11830133 is back on 4 wheels!

[68911USA]

Just happy to have finally been able to take the old 911 back down off of the jack stands- it's been months of fooling with the brake lines, master cylinder, and lines, replacing the speedo drive gear, and general cleaning and inspection. Rebuilding the pedal cluster has also helped it greatly. I had to adjust almost an inch into the length of the clutch cable to compensate for the new bushings, the cluster had absolutely no bushings in it before. Perhaps if it would stop raining for more than two hours, I could road test it...wish me luck!

[B D]

Looking good! Can't wait to get my car buttoned up and back on the road as well.

[joegt3cup]

Looking good! Can't wait to get my car buttoned up and back on the road as well.

Add me to that list !

[68911USA]

HAA! Just drove it for the first time since October. What a difference. The clutch is perfect, but the brakes are obviously very spongy still. I have to pump-pump-pump them at every stop to build a firm pedal. I am very, very tired of bleeding the brakes. Looks like up on the stands it goes again before any serious driving. Sigh. But, what a nice engine- smooth, smooth, smooth!

[68911USA]

Okay. Just put another 50 miles on it on the famous Natchez Trace Parkway near my house. Nice and open, no traffic. Brakes still suspect.

1. Still pump-pump-pumping to get firm pressure, although the car does stop without any drama besides the mushy pedal feel.

2. At a dead stop, I notice that the brake pedal stays down a couple of inches from the level of the clutch pedal. If I sort of "pull" it with the side of my foot, it comes back up to level again.

3. Is this more likely a function of:

a. The master cylinder is shot. (PO swears he put a new master cylinder in it two years ago, and it is a 19mm in it now.)

b. The brake return spring is shot on the pedal cluster. I replaced all bushings but did not do springs.

c. Needs continued brake bleeding- that is, if I can get the brakes bled right, this will most likely go away.

I am so tired of brakes. Was fun driving the car, though.

[orange911]

Bleed the brakes correctly first. Assuming the fluid is new, you do not need to change it out. If they are still mushy, I would suspect a bad seal in the mc, but you would see fluid on the inside of the car, and the level would drop. Lastly, make sue your hoses are in good shape. If they are expanding too much from old age, then you would get a mushy feel,but not likely requiring pedal pumping.

My guess, your lines need some serious air purging.

Edit: Just saw that you have to force the pedal back. This would indicate that the rod is not moving smoothly through the seal, or as you have already see, the return spring is shot. I had assumed that this was replaced when you rebuilt the pedal cluster. Yank that out and have a do-over.

Also, make sure that the MC reservoir level is not dropping too low when bleeding. Make sure the assistant helping holds the pedal down while you tighten the nipple. Careful not to force the pedal down too far, you can damage the seal by forcing it into parts of the MC that may be rusty from lack of cleaning from normal use.

[68911USA]

After more (careful!) driving, the brake fluid level does not drop, so I think the return spring is going to be the culprit, and perhaps a little binding in the MC as well. I'm going to put some lithium grease on the brake-pedal-to-MC shaft and see if that helps also, I did not lube it when I reinstalled it. Thanks very much! After all I've done, taking that pedal cluster apart again to replace that spring just makes me want to cry...