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Squishy brake pedal on 93 w/ABS normal? 200

I just finished some brake work and I continue to have a very squishy brake pedal after trying multiple ways to resolve the issue. Here are the facts:

93 240 210kmi
When I purchased it 3+ years ago I installed new calipers, pads, SS brake lines, ATE MC, ATE Dot 4 fluid using Motive pressure bleeder @ 20#. Everything worked ok. Pedal was somewhat squishy and figured it was normal
This past summer, replaced fluid with ATE Dot 4 and Motive pressure bleeder. Seemed to go ok.
Recently the LF brake caliper seized, which I just replaced and bled just that line (see earlier post this week)
At this point the pedal got more squish and goes almost to the floor with the engine running. Never had this in the past.
Decided to bench-bleed the MC just to be safe
Re-bled the entire system in this order per the green book: LR, RR, LF, RF
No change in pedal - still squishy to the floor
With the engine off, the pedal is firm after 2-3 inches of travel

The only thing I've not touched is the ABS modulator. Should I try bleeding that? If so, what is the procedure?

I've heard others say this kind of pedal behavior is normal for a 93 w/ABS. I'm expecting the pedal to be much more firm.

Any other thoughts?

Thanks.








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    ANSWER Squishy brake pedal on 93 w/ABS normal? 200

    Problem solved.

    First I bled the ABS modulator - all 3 outlet ports - got some air out, but not a big deal.
    Next I bled each corner - LR, RR, LF and then RF. I took about 1 pint from the LR before all the air was gone. That was surprising to me.
    The RR showed no air at all (expected) but still pulled 1/2 pint to be sure.
    The fronts showed some air from breaking the ABS modulator connection, but were clean after that.

    In the end, I think I had not bled enough the first time. I ran two full quarts through the system and the brakes are nice and tight now. No leaks, no drips anywhere. Very happy.

    Thanks for all the suggestions.

    This post has been marked as an answer to the original question.








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    Squishy brake pedal on 93 w/ABS normal? 200

    Problem solved.

    First I bled the ABS modulator - all 3 outlet ports - got some air out, but not a big deal.
    Next I bled each corner - LR, RR, LF and then RF. I took about 1 pint from the LR before all the air was gone. That was surprising to me.
    The RR showed no air at all (expected) but still pulled 1/2 pint to be sure.
    The fronts showed some air from breaking the ABS modulator connection, but were clean after that.

    In the end, I think I had not bled enough the first time. I ran two full quarts through the system and the brakes are nice and tight now. No leaks, no drips anywhere. Very happy.

    Thanks for all the suggestions.








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      Squishy brake pedal on 93 w/ABS normal? 200

      My take is that 240's (ABS or not) are difficult cars to bleed all the air out of their brake systems. I remember doing way too many bleeds on my 1990 244DL (non-ABS) to get all the air out!

      Brakes are definitely not a strong point of these cars! I spent a lot of money on brake parts and a lot of time replacing parts and bleeding the system afterwards on my 90. My 95 850 (251k) is better and my 2002 Passat brake system is bulletproof compared to the 240's.








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    Squishy brake pedal on 93 w/ABS normal? 200

    No.

    A squishy brake pedal indicates air in the system, a bad master, or a leak. A squishy pedal to the floor indicates a non-driveable car.

    Bleeding it should eliminate air, but you may have to go around the system a couple times. You did get new fluid out of the LR before you moved on, right ?

    Given that you did all that, do you have brake fluid in the vacuum line ? Are there oil spots under the car that are not in the center ?

    Greg








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    Squishy brake pedal on 93 w/ABS normal? 200

    "At this point the pedal got more squish and goes almost to the floor with the engine running. Never had this in the past."

    Existing MC should never have to be bench bled unless you run it accidentally out of fluid.

    If the issue has gotten worse and it is not just a perception problem (comparing it unconscious) to another car you recently drove) You have an issue. It is either a failed MC (unlikely at three years) or you have air...and lots of it if the pedal goes to the floor...in one or more circuits.

    I will be honest that I do not know a procedure for bleeding the ABS modulator on the early Volvo system like ours. I know on old first gen GM systems is requires a specific order to set a home position on the pistons...I am pretty sure the Bosch systems did not require this.







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