Update/Conclusion at the bottom
Okay, I have a full Corrado G60 11" front brake swap on my GLI. Here's a list of the parts in the entire braking system:
-Brand new aluminum ATE master cylinder 22mm
-Brand new (rebuilt) Girling 54 front calipers
-Brand new (rebuilt) Girling 36 rear calipers
-Brand new PBR MetalMaster pads (front and rear)
-Brand new GLI proportioning valve properly adjusted to compensate for lowered ride height
-Brand new Autotech stainless braided lines (all 6 of 'em)
-Brand new hardlines (all of 'em)
-Brand new Castrol GTLMA DOT 4 fluid
What I'm trying to say is the entire braking system is NEW.
The master cylinder was properly bench bled before installation.
The entire system has been bled through completely THREE times now! The fluid is clear and clean each time w/ no bubbles.
Brake fluid is at the proper level in resevoir.
I have checked the system through entirely multiple times for leaks. There are NO leaks.
1.) When I push the brake pedal, I get almost no response until the pedal is more than halfway through its travel.
2.) It feels soft when it finally does engage the brakes. However, if I sit at rest, I cannot push the pedal to the floor (as if it were leaking) but it does feel soft.
3.) It is too high effort to stop the car and I really need to stand on the pedal. This thing should stop like it slammed into a brick wall.
My brother has the exact same setup on his '92 GTI and it is wonderful! The pedal is high, hard, and the car stops on a dime with little effort.
The only variable left in the system that I can see is the vacuum booster. I'm not entirely sure how it would give the results I'm experiencing if it was worn out or leaking, but maybe?
The booster is original to the car (which btw, came with 9.4" front discs) and has 205,000 miles on it.
Modified by '88Jetta16v at 8:13 PM 10-1-2009
Modified by '88Jetta16v at 12:59 AM 10-11-2009