Brake pedal travel

[minorjohn]

Dear Members.
During the pre MoT on my 1966 1000 convertible, my inspector reckoned there is too much overall brake pedal travel. I found that the free play indeed measured 1 inch and have successfully adjusted it to the correct 3/4 inch, which seems to have made quite a difference. However, in doing so, I noticed the following :- My pedal seems to have 2 distinct resistances, the first is the obvious 3/4 inch pedal movement before the push rod touches the hydraulic piston, but then there is an initial slight and constant resistance for about a further 1/2 inch travel, BEFORE the full pressure starts to build. Is this normal, or could this be an indication of wear in the Master Cylinder and a replacement might be a good idea ?
I should mention that the car and brakes are completely standard and they work really well.
Finally, what is the correct Master Cylinder fluid level ? BMC workshop manual says 1/2 inch below threads, Haynes, 1/4 inch, but the actual filler cap says, "Fill only to the bottom of neck" !! ??
Safe driving,
John.

[bmcecosse]

Just sounds like you need to adjust up the brakes - they don't self adjust! Don't fret about the level too much - it's hardly critical - but must not drop stupidly low of course.

[DAVIDMCCULLOUGH]

I keep the level on mine to the bottom of the threads, there is a pin hole breather in the cap that can get clogged up with dirt and underfelt so its worth checking that this is clear when its off.

Re pedal travel, if the pedal shaft is worn the travel is usually more. So long as there is some free play between the pushrod and the master cylinder it should be fine, if its too close the pressure can build up and can the brakes to lock on.