Hi,
I have read some things about the failing plastic washer in the brake modulator and I think Richard also wrote about a clicking in the pedal being an early symtom.
I have a regular little click about in the middle of the brake travel and also when I sometimes brake (usually at slow speeds) the pedal feels like when the ABS is kicking in (fast series of feelable clicks in the pedal) even though there is no reason for the ABS to engage (tarmac road, slow braking)
Is that an early symtom of this issue ? Mine ist a 98 GEMS.
And what would be the remedy, I have read about a quite complicated repair, exchanginf the washer for a stainless steel one. Or complete modulator exchange with a used one from a later Model ? Is that possible or is that incompatible due to the different Traction control (2/4 Wheels) ?
greetings,
Max.

Mine has had the clicky pedal ever since I have owned it, it is only just recently another strange thing has occurred (very long pedal after 120 miles without touching the brakes). As with any brake issues, the first thing to do is to bleed the brakes following the full RAVE process and see if it goes away. If you are left with just the clicky feel, I would ignore it as I have with mine. It may be a symptom of the broken plastic bit or it may just be a bit of wear at the point the pedal joins the brake actuator rod.

You can fit the later unit but that is quite a process as the later ones have 4 wheel traction control so you have to change the ECU and do some wiring mods. A full write up of what you need to do is here https://drive.google.com/file/d/1DBMo28K-ZaOw6bn9xa5Ze8yjAuVOPe2V/view?usp=sharing

I also wondered about getting a later modulator with the stainless washers and swapping just them over into an earlier modulator rather than spending around £150 on the kit. No idea how feasible that is and I would need a pair on modulators to strip down side by side. I have a non-TC modulator from a base spec car and was going to pull that apart but someone wants it so I've said he can have it as they are so rare with so few base spec cars having been made.

Bleeding sounds like a good idea, thanks.