Pedal Box Rebuild - Hard Brake Pedal and Soft Clutch Pedal

[Leucadian]

So I just rebuilt my pedal box with IE kit, and a new master cylinder.  Got everything back together, bled the clutch line (5 speed) at both the slave cylinder, and at the master cylinder with a power bleeder at 15 psi.  Saw some bubbles coming out at the power bleeder when I slowly pumped the clutch pedal, after a couple pumps, the bubbles stopped.  Topped the reservoir off and still ended up with a very soft clutch pedal, with basically no resistance.  I checked from the reservoir to the slave, and didn't see any leaks anywhere, and the fluid reservoir isn't losing any fluid.  Potentially still have air trapped in the MC?  Bad slave now?  The transmission was swapped to a 5 speed 2 years ago, so the slave isn't that old, and no signs of leakage at the slave.  I've since bled the system 3 times with no luck.  

 

On top of that, my brake pedal has only about 2" of travel.  I made sure the through bolt at the pedal box/booster assembly wasn't overly tightened, and lubed everything back up.  Turned the car over, and still, maybe 2-3" of travel.  The pedal assembly shouldn't be too tight because the clutch pedal has free travel

 

Also, is there any trick to pre-loading the spring for the throttle pedal on the outside of the pedal box?  I can get the spring over one rotation, but it doesn't allow me to fully seat the throttle arm.

 

So fully re-built pedal box with a non-functioning clutch, brake and throttle...

Edited February 7, 2021 by Leucadian

[Son of Marty]

2" travel on a rebuilt pedal box with good brakes sounds about right to me, for the clutch is the bleeder on the slave cylinder pointed down? it should be for a 5 speed.

Edited February 7, 2021 by Son of Marty

[Leucadian]

Slave cylinder pointed up.  

 

Seeing as that there's new fluid in the lines, can I try reverse bleeding, before having to flip the slave?

Edited February 7, 2021 by Leucadian

[Son of Marty]

You'll need to turn it over then it's drilled so that it mounts with the bleeder pointing down.

 

 

Edited February 7, 2021 by Son of Marty

[Leucadian]

Well, problem found.

 

 

Taking the slave off of the 245 was nowhere near as bad as I thought it would be.  Just took a few extensions and joints, didn't even have to move the tranny.