HAN is a great forum..lol just not for brake questions.

well here is the rest of the story incase anyone stumbles across this

OK. rebench bled the MC. with a better setup that did not allow any air back in. i realize now the old bench bleed setup did allow the suction of a few air bubbles back into one port on the MC.
-regreased the piston on the MC, the seal, and the rod on the booster
-reinstalled it on the booster. double checked torque specs for MC-booster
-cleaned out the resevoir basket (it now had rusty particles inside the basket. ??) topped off fluid.

to eliminate any chance of somehow super offsetting the chambers of the mc we only bled each caliper about 5 times. last time we started off fully bleeding the line (15-20 on the rear). we successfully did the RR, and then the left front again. now we were at the left rear. the same place it went POP last time. we start off bleeding and have LOW pressure. hardly much coming out the bleed line. on the 3rd bleed i feel a big wiggle in the bleed line and then BAM we have full pressure again!! bleed about 3 more times. good solid pressure.

we finish the sequence. top off the fluids again and went all the way around successfully a second time, still only bleeding about 6 times on each caliper. i think i might run the engine and see what i feel. if all is well i'll do a full bleed.



well.. bled the car until there was nothing but brand new clear fluid coming out the end. kept testing the brakes with the engine on and off. pedal felt normal. but possibly a bit low and still perhaps a bit squishy. not sure if i'm paranoid now or what.
dropped the car off the blocks and took it around the blocks and parking lots. i don't know what else to say but... it works? brakes are working, ebrakes are working (might need a bit more tightening) but all in all...everything seems to be working? the pedal may be a bit low and squishy. could this be attributed to shitty ass old rusty rotors in the back? i used the ones that came with the swap.

as you can tell i'm still cautious about it all. i'll do nothing but drive it around just the closest blocks before i have full faith in the brakes.

One of the good things that always comes about when i do a project: i make a writeup

"How to Swap your Brake Master Cylinder and brake booster"
http://www.lukekailburn.com/boostermc.html



-Luke