So,
They bled fine. Went round the whole car twice.
Air on the first flush as you'd expect with brand new lines. Then crystal clear clean fluid with no air at all on the second bleed. Master cylinder set bled each time to be sure. ~20psi pressure on the EZ bleed.
I pressed the brake pedal.
It felt CRAP!
It didn't drop to the floor, it was obviously moving fluid and pistons somewhere, but first impression was very soft.
I pumped it a few times. And wasn't happy with the action at all, so went round the whole car and bled the whole lot again to be sure there wasn't an airlock or similar somewhere.
Pedal STILL rubbish.
It also sounded odd. It was as if I could hear 'fluid noises' as I pressed the pedal.
I applied a constant pressure to the pedal, and as I held the pressure on the pedal slowly sank to the floor under sustained pressure, as did my heart
I continued pumping at the pedal a good few times more, then went over the whole car again checking every single fluid union. Not a drop evident at any of my joints, or any of the calipers.
It was then I noticed there seemed to be brake fluid on the bottom of the servo. Very strange
It was almost as if fluid was leaking out from inside the servo. How bizzare.
I cleaned the servo off totally, then pumped the pedal a few more times.
The fluid level in the reservoir seemed to be going down very slightly, but nothing visible on the servo immediately.
5 minutes later though, and the servo was damp again.
I removed the MC, and whilst it's very hard to say for sure, it LOOKED like there was evidence of fluid on the plunger rod on the back of the master cylinder.
Current thoughts are that my brand new Pagid master cylinder from ECP is faulty from new, and is bleeding fluid past the seals and leaking into the servo.
Second issue is that it's then leaking out of the servo, suggesting that the servo isn't as air tight as it really should be!
Im going to speak to ECP about a return on this dodgy MC, and also grab my spare servo from storage and have a think about fitting that. I might rig up a DIY pressure tester to check both servos before attempting any work.
Has anyone ever removed / changed a servo? It looks like the bolts are accessed from inside, and I can't imagine they're going to be too enjoyable to reach at all!
Argh. Car. Why do you treat me this way?
I won't be beaten though. Never give up, no matter how much you want to.
I think I've earnt another beer this evening