Last night I tried the Foster approach and clamped all the rubber brake lines with C-clamps. The pedal was high and hard. I removed the clamp from the left rear line and I still had pedal. I then removed the clamp from the right rear line and I still had pedal which means the rear brakes are fine. I then removed the C-clamp from one of the right front lines and the pedal was not as hard and went down a little, but not to the floor like before. I bled that line until I had a hard pedal again and then removed the second C-clamp from the right front and bled the caliper again until I saw no more air bubbles coming out and the pedal was hard.

I was almost home free when I went to the left front and removed one of the C-clamps. The pedal went down like it had done on the right side, so I followed the same procedure bleeding the left front caliper. While bleeding the second line, the @#$%#$ pedal sank to the floor again! Darn it....!

I clamped off all the lines again and the pedal still sank to the floor this time. I removed the brake lines from the MC and reinstalled the plastic plugs.
The pedal was no longer hard and slowly sank to the floor which means the MC seals were probably toasted while bleeding the front calipers. This is the second MC I have installed. The first was leaking fluid behind the MC into the booster. Took it back and got another one and now that one is bypassing internally because it now fails the dead head test with the plastic plugs.

So now I have another decision to make.....

1)Install a new (not rebuilt) MC, and try again.
2)Throw in the towel and let the Volvo shop finish the job.

So it would appear that there was some air in the front calipers despite pressure bleeding the system, but now the MC is toasted again, possibly from my wife pushing the pedal while we were bleeding the front calipers.

So what would you guys do from here... Go for another MC or call the tow truck and be done with it? I put the wheels back on last night just in case I decide to have it towed this morning. I'm calling Carquest to see if they sell "NEW"
MC's because the rebuilt ones are not holding up very well and appearently they are not recommended by brake repair shops.

Special thanks goes to all of you guys who have stuck with me through this and especially to Don Foster for his C-clamp recommendation that helped me quickly analyze where the problems areas were. I thought sure I had it licked until the pedal went soft again. I have to return the rental car today so I have to decide whether to make another repair attempt with a new MC or just give it up at this point.

Your thoughts and opinions would be appreciated.... what would you do?

DeWayne