With the engine running at idle and the shift lever in neutral, depress the brake pedal and hold a constant foot pressure on the pedal. If the pedal gradually falls away with the constant pressure, the hydraulic system may be leaking. Perform a visual check to confirm any suspected leak.
Check the master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear, an abnormally low level in the reservoir indicates an external leak in the system. The hydraulic system may be leaking either internally or externally.
The brake fluid reservoir supplies fluid to the clutch hydraulic system on vehicles with a manual transaxle. Be sure to check for leaks in the clutch hydraulic system if an abnormally low brake fluid level is indicated in the reservoir.
Improper brake fluid, mineral oil, or water in the fluid may cause the brake fluid to boil or the rubber components in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evidenced by swollen wheel cylinder piston cups on the drum brake wheels or master cylinder fluid reservoir cover diaphragm.
If deterioration of rubber is evident, disassemble all hydraulic parts and wash with alcohol. Dry these parts with compressed air before assembly to keep alcohol out of the system. Replace master cylinder assembly as necessary. Replace all rubber parts in the system, including hoses. Also, when working on the brake mechanisms, check for fluid on the linings. If excessive fluid is found, replace the linings.
If the master cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If condition is not found, drain fluid, flush with brake fluid, refill, and bleed the system.