Brake pedal travel and sponginess in '84 Spider?

[AlfaNeely@xxxxxxx]

       I have exactly the same problem with my 84 spider race car.  Too much 
pedal travel.  The brakes work fine.  It is just disconcerting to have the 
pedal engage so close to the floor.  It also makes heal toe more difficult.  
       I made sure the new master cylinder was the larger 22 mm size.  I am 
thinking of searching for a 24 mm master.  Plus I have not replaced my brake 
booster.  I was thinking that might be the problem.
       There is no adjustment in the linkage.  I have been thinking of pullin
g the parts off and making sure there is no slop in the linkage and that the 
push rod in the brake booster is extending into the master cylinder the 
correct amount.
       If the problem happens only after the car is driven, then the rotors 
could be warped.  The rotors could be pushing the brake pads away from the 
rotor.  Then extra travel is required to move them back to the rotor.  If the 
first pump requires a longer stroke, but after that the pedal rises, that 
could be your problem.  However, my race car pedal has too much travel all 
the time.
       The thickness of the rotors and the amount of brake pad remaining will 
not change the stroke required.  More fluid will be in the calipers when the 
parts are worn, but the stroke to apply the brakes should be the same.
       I have found that the pedal on various Alfa spiders will vary even 
though all the parts are the same.
       Let me know if you get any good suggestions off line.

Ciao,
Russ Neely
Oklahoma City

In a message dated 3/31/2003 4:26:23 AM Central Standard Time, 
owner-alfa-digest@domain.elided writes:

> Date: Mon, 31 Mar 2003 00:11:07 +0000
> From: JeffreyOlson@domain.elided
> Subject: Brake pedal travel and sponginess in '84 Spider?
> 
> Just replaced:
> 
> Brake booster
> Brake master cylinder
> Brake hoses (2 front/1 center)
> Front pads
> Rebuilt all four calipers
> 
> Problem is I still have a significant amount of pedal travel and spongy 
> brake 
> feel after bleeding the system several times the old-fashioned way and with 
> a 
> pressure bleeder.  Same problem existed BEFORE all the brake work.  No 
> fluid 
> leaks.  
> 
> System feels like it still has air somewhere.  Brakes otherwise work well 
> but 
> require one or two quick pumps.  Main concern is the excessive pedal 
> travel.  
> Brake rotors are well worn but still have some life left.  Pedal has 
> pressure 
> behind it near bottom end of travel and does not sink to floor like there 
> is a 
> system leak.
> 
> Any ideas?
> 
> Thanks!
> 
> Jeff
> Davidson, NC
> 
> '84 Alfa Romeo Spider Veloce (Resurrected, stupidly...)
> '78 Alfa Romeo Spider (just SOLD Friday to a good Alfisti home in VA!)
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