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Old 27th September 2009, 20:57
sylvazx sylvazx is offline
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I hope i am not repeating something you may have already been told but have seen similar to this before. the cause was to much preload on the master cylinder from the brake servo. This was cured by removing the master cylinder from front of the servo, the rod that sticks out the end of the servo and protrudes into the master cylinder was slightly too long ( gives a very high brake pedal especially when brakes hot). on some cars there is an adjuster on the end of this rod which can be screwed in and out, adjusting the preload on the system. have not removed the master cylinder on my own 5exi to check if this is present on my servo but if not present in your own then the preload could be adjusted by removing small amount of metal from end of rod with a file or placing a couple of thin washers on the master cylinder mounting bolts before refitting the cylinder to the servo. As these are safety critical items you are dealing with please recheck operation before driving.
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