I am looking for ideas. I have a 62 544 with the brake reservoir. I have three different master cylinders that I have rebuilt but am having brake issues. I bled the brakes again today and I still have a very soft pedal. Fluid came out solid out of each bleeder and I had pedal. I went to drive it and the pedal is soft to no pedal. The car also pulls heavy to the left. It will brake but the pedal goes to the floor. The wheel cylinders were also rebuilt. What am I missing?

Looked today and saw this wet area. There does not feel like there is any play in the pedal. I rebuilt this Master. Before I take it all apart again is there anything else I can try? I can pump the pedal up.
[URL=http://s1101.photobucket.com/user/lelshaddai/media/1962%20Volvo%20PV544/2016-02-10%2017.10.17_zpsmmflzd3h.jpg.html][IMG]http://i1101.photobucket.com/albums/g432/lelshaddai/1962%20Volvo%20PV544/2016-02-10%2017.10.17_zpsmmflzd3h.jpg[/IMG][/URL]

Here's your picture.

It appears your brake master cylinder is still leaking.

If there is fluid inside the dust boot your problem is with the internal seals or bore.

If the bore is to badly damaged, IE pits and grooves, you have to replace with a new brake master cylinder or have your old 1 resleeved.


--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502

Are you sure you have each of the wheels adjusted properly. If even one was set with too much clearance the pedal will be low on first application--come up with a second step. That could also account for the pull. I'd try re-adjusting--setting each too tight--just loose enough so you can turn the wheel with drag and then see what the pedal feels like. I tried to see your photos but the images couldn't be found (that may be on me--not the most computer savvy person). -- Dave

How were the brakes before you started?

Perhaps you have put some of the shoes in the wrong locations. In front, there is a short shoe and a longer shoe on each side.

Also, look at the hoses when someone steps on the brake when the pedal is soft - could one have a soft spot?

One thing that you could try is to clamp each hose when the brakes are soft, perhaps you can find the problem wheel.

When I got the car the brakes were bad. I rebuilt the Master and wheel cylinders. I will check on the shoes. Is short in front or back? I noticed today a puddle under the Master that I will look to see were it is coming from.

The short shoe goes toward the front of the car. I agree with others that the small hole in the master cyl. Is probably covered. That could also cause the brakes to drag if you drive it long enough for the fluid to warm up and expand with no way to go back to the reservoir.
I have a 65 544 and have had trouble with fluid leaking from the firewall mounted reservoir usually around the MC cap. Tom

Is it possible that there is no free play in the master cylinder pushrod?

Some M/C pistons are different lengths. The pushrod needs to have some slack so that the piston will clear the equalizing hole. You can access this equalizing hole thru the filler hole on the M/C. Stick a piece of wire into this hole to see if the piston is clearing the hole.
I believe you should be able to move the piston forward .5mm before it hits the wire. Hope this helps. Larry