Corksil

Yesterday I completed fully rebuilding my CRX brake system. I used Integra front calipers, and Del Sol rear calipers. I used an Odyssey 1" MC and booster. I made custom hardlines everywhere but to the rear calipers. I used a 4040 prop valve from an Integra and have 'tucked' my prop valve under the dash. I have stainless braided 'softlines' connecting calipers to the hardlines.

After bolting everything up and tightening all the flare nuts, I added fluid and started bleeding the system in the proper order. Everything bled out fine, but there might be a little air in the system still. The pedal feels pretty stiff but I need to get more DOT3 before I can bleed it again.

I only have one leak - which is very very tiny when I put a lot of weight on the pedal. The prop valve leaks from behind the rubber plug in the side. I pulled it out of a spare prop valve for inspection and it's not a hermetic seal at all. It's just a rubber plug in the side, like a weep hole on a water pump.

I'm hoping this tiny dribble is 'normal' when a system is completely empty of fluid and filled/bled for the first time. I'm hoping there is a valve inside the prop that allows air bubbles out but not in - also the color of the fluid leaking out under this rubber plug is cloudy and dirty. The fluid that comes out of the calipers is clean and fresh.

Here is a pic. It leaks from the rubber plug (removed in the picture, held between my finger tips)


The pictures are from a spare prop valve I had, not the 4040 that is hooked up. This is another old prop valve, you can see where the plug is before I removed it.


Does anyone have experience with a 'leaking' prop valve from underneath this rubber plug?

Thanks!

MAD_MIKE

Not on a Honda, but on other makes that rubber plug is the backside of the proportional valve(unpressurized). If it is leaking the PV seals are leaking. AFAIK no one makes rebuild kits for these. Just need to purchase a new valve.

Corksil

Thanks, it doesn't seem to be leaking after a run up and down the street and the brakes feel fine (a little spongy, I will bleed them again when I get more DOT3.)

Has anyone experienced this or something like it ever before? I can't be the first, on honda-tech of all places..

Tyson

its not common but ive heard it happen a few times.

Corksil

Thanks a lot for the info Tyson.. it's great to connect with someone who has been there before.

I picked up a gallon of DOT3 today, I will bleed the **** out of the entire brake system until I am 100% certain that there are no air bubbles in the system. Then I will jack up each wheel on the car and turn the axle nuts/hub nuts until I am sure that all four calipers will lock up the wheels and make sure I don't have any dragging calipers when the pedal is released. Then I will adjust both (new) parking brake cables and keep the parking brake on after violently ripping the handle up in an attempt to stretch the new cables and readjust them after a day or two.

Once I have verified that the entire brake system is solid, I will do a few 'panic' stops and lock up the wheels HARD at adequate speed.

After all that I will check for ANY leaks or weeping from under the rubber plug. I suspect my problem will disappear, but if It doesn't I will replace the prop valve with another 4040.

I want to make sure this entire brake system is 100% functional and operational before I get onto the track and try to haul the car down to 20mph from 100+ and have something let go and send me into the wall at high speed .

I will report back with my findings. If there is a better way to test my brake system, please advise.

Thanks again homie!

Tyson

why are you attempting to reuse that?

its done.

Corksil

Was your post implying that my prop valve is bad and should be replaced?

Perhaps I misunderstood.

How much for a 4040 shipped to 96708?

Tyson

you cant fix the leak.

you sure as hell cant fix it by taking the rubber completely off.

sorry, im not selling any at the moment. maybe i have them available, but its not worth my time at the moment. look on ebay.