Author Topic: Lucas calipers on a golf 2 which master cylinder???- Help (Read 4569 times)

DonGTI · « **on:** March 27, 2008, 11:52:37 pm »

Hi all

I recently upgraded my friend's golf 2 from a 1.6 diesel to a 1.9 aaz ... although we replaced everything on the front end for new including brakes and used ebc green stuff, he still complained about the lack of stopping power.

I had a pair of hubs+knuckles I had bought for my project that came off a 1996 1.9 tdi golf 3 as well as a mk2 gti rear axel complete with brakes and decided to fit those. After refurbishing the calipers (Lucas type) and putting in new bearings, hubs, disks and pads and bolting everything on, we waited 700 miles for the pads to bed in.

The problem now is that after repeated bleeding of the brakes and replacing all brake lines for new there still is increased brake pedal travel... I am blaming the increased diamiter of the pistons on the front calipers as well as the upgrade to calipers at the back...

Any idea what master cylinder do i need to fit?
I have the following running around but no idea regarding their piston size: Golf 2 gti (1988) Golf 3 TD (1993 (solid front disks and rear drums) Seat Cordoba TDI (vented front with lucas calipers but rear drums)
would any of the above mentioned do the job?

Thanks
Daniel

DonGTI · « **Reply #1 on:** March 29, 2008, 12:54:26 pm »

anyone?

please :?

zukgod1 · « **Reply #2 on:** March 29, 2008, 04:00:56 pm »

what master is on it now?

burn_your_money · « **Reply #3 on:** March 29, 2008, 07:08:54 pm »

take the vacuum assist out of the booster and put your thumb over the end of it. Rev the engine up a bit and see how much vacuum it's making.

DonGTI · « **Reply #4 on:** March 29, 2008, 11:06:13 pm »

zukgod1: right now it is running:
stock Golf2 master cylinder for front solid disks and rear drums
however it has:
Front Golf3 Lucas calipers (almost 8mm wider piston diamiter than stock Golf2 items, even gti) with vented disks + rear calipers with solid Golf2 gti disks

burn_your_money: Had vacum problems following swap, pump was not producing vacum, replaced it with new in box item. Had vacum leak in pipe because pedal was stiff, replaced pipe from vacum pump to servo assist and now pedal feels normal.

problem is that first 1 cm of brake pedal travel consistently produces no results whatsoever. Owner of veichle started checking all other possible causes:
Brake lines (solid and plastic) replaced all
Replaced hydraulic in lines and master cylinder (Dot 4)
Serviced calipers before assembly, no sticking calipers
Replaced master cylinder with item exactly like it (took it to vw dealer and replaced it by part number)

Does anyone have any charts of master cylinder sizes?