My son's '94 940 sedan (the one that had the siezed turbo) has been experiencing a low brake pedel. The pedel does not go to the floor, but it is close. When the pedel firms up, it stays firm. But, there is a lot of travel to get to this point.

What we have done:
New master cylinder
New brake booster (replaced to solve cold weather problems)
New brake hoses on all 4 wheels
Bled system well, twice. There is no air in the system!

The low pedel problem existed before the master cylinder and brake booster were replaced. The push rod from the new brake booster was set correctly when purchased. As a test, I had my son very slowly push the brake pedel with the bleed ports on the master cylinder open in order to see how much travel was needed before brake fluid started to flow. Brake fluid started to flow almost immedaitely, (maybe 1/2" to 3/4" pedel travel). We bled the system at all 4 corners with both a pressure bleeder, and by pumping the pedel. None of the calipers have any evidence of leakage. The system is not loosing any brake fluid.

I am stumped as to why the pedel is so low. Is there something I am missing? Is there a special way we need to bleed the ABS modulator to purge hidden air?

My son is used to the low pedel, but I don't see it as safe. Any thoughts from the board greatly are appreciated.



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Gary D