And the winner is... I'm not sure. We installed a new proportioning valve, and the pedal still sunk to the floor. So we got out the razor blades, rolled up our sleeves, then decided to try a few more things.
We drained the entire system, re-installed the new MC, and installed braided flexible lines. At the same time we swapped the MC, we also installed two small shims to adjust the free play in the pedal. Pressure bled the system, no big change, pedal bled the system, voila! It all seems to work now! So, it was either the shims or the flexible lines. If you suggested either of those, give yourself a pat on the back! My guess is it was probably the lines, although the ones that came out look to be in very good condition. The shims certainly did raise the pedal (maybe too much, although I dread taking one of them back out!). Thanks all for your suggestions and help. In the fwiw dept.. We used a pressure bleeder, a good one with a cap made for the Alfa reservoir. It was useful initially to prime the system, but it didn't do a good job in getting all of the air out of the system. We resorted to the old two man pedal bleed, and that did the trick. We didn't have to raise either end of the car. YMMV. bs -- to be removed from alfa, see http://www.digest.net/bin/digest-subs.cgi or email "unsubscribe alfa" to [email protected]
