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xflyer Samba Member
Joined: June 15, 2006 Posts: 314 Location: SOCAL
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Posted: Wed May 21, 2025 9:24 am Post subject: Re: Brakes needing to be pumped after new master cylinder |
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A possible clue here is the report that installing the pistons into the calipers was difficult. The square profile O ring caliper/piston seal may have been distorted. In normal operation the seal deflects when the brakes are applied and when the pedal is released the seal returns the piston into the caliper. That's so the pads do not drag excessively on the rotor. If the seal is distorted the piston may not extend correctly.
Try this: With wheels off the ground have someone push on the brake pedal while you spin the front wheels. See how long it takes (pedal travel or pumping) to stop the wheel. Then let off the pedal and watch the pads and see how far they retract. Should be barely visible, but the wheel should turn freely, there will likely be some rubbing of the pads on the rotor, as long as there is no excess drag its OK.
If the pistons retract a lot the calipers may need repairing. May need new O rings. _________________ 1989 Campmobile, 1984 7 passenger beater Vanagon
Both with cool A/C |
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Nekobus Samba Member
Joined: May 16, 2024 Posts: 2 Location: CA
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Posted: Thu May 22, 2025 10:20 pm Post subject: Re: Brakes needing to be pumped after new master cylinder |
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Just wanted to say that I was having a similar issue in my 90 Multivan and a new brake master cylinder solved the problem. |
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brewvan Samba Member
Joined: March 21, 2025 Posts: 26 Location: Loomis california
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Posted: Fri May 23, 2025 7:16 pm Post subject: Re: Brakes needing to be pumped after new master cylinder |
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Bone head move of the year. I installed the calipers on upside down… bleeder screw was lower than the trapped air in the cylinder. Brakes are working great now. Thank you all for the help! |
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MarkWard Samba Member

Joined: February 09, 2005 Posts: 18773 Location: Retired South Florida
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Posted: Sat May 24, 2025 4:00 am Post subject: Re: Brakes needing to be pumped after new master cylinder |
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Thanks for the update. The experience curve can bite at times. Probably should thank Go Westy for going above and beyond with you. That has been my experience. |
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xflyer Samba Member
Joined: June 15, 2006 Posts: 314 Location: SOCAL
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Posted: Sun May 25, 2025 8:38 am Post subject: Re: Brakes needing to be pumped after new master cylinder |
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Turns out it was a problem with the calipers, but not the way I had theorized. This type of situation, calipers on opposite sides, is why in aircraft maintenance a second or even third set of eyes is on the procedure before things go back into service. _________________ 1989 Campmobile, 1984 7 passenger beater Vanagon
Both with cool A/C |
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