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I think I've read all posts concerning brakes, so here goes. '88 240DL, 160K, stick, remanf. rear calipers, new MC, new rotors, front calipers off a '91 240, bronze junction off same car, meticulous repeated bleeding after every process as I progressed into the morass.
Major things which I observed: Brakes improved after rear calipers and rotors and pads installed. Next, the front left caliper went on with bearings re-greased and adjusted, and after bleeding, during a short spin, brake failure light comes on and I quickly go home. Bentley said, MC must be bad as pedal had no brakes now. This is when I noticed the first chamber of the MC squirting brake fluid up, like a small volcano, into the reservoir every time I pushed the pedal in. I could see it, vroosh, up it shoots. So, new MC.
Install new MC, you guessed it, vroosh! Vroosh, vroosh. No brakes. Next, install right front caliper, rotor, re-do bearings, assemble bleed, and vroosh.
Thought about it two days, checked everything circuits etc., and install the beautiful '91 bronze junction, minus the troubesome switch. Checked all, and vroosh, to the floor, no brakes.
Let it sit two days, start looking it over, surprize, the front calipers halves were mixed up, so, took em off, cleaned up, assembled corrently, pushed the pedal, and vroosh. No brakes.
New calipers all around, new MC, new 8 point coupling, new fluid and bleeding. The new MC first chamber continues pushing fluid straight up into the reservoir everytime I push the pedel, no brakes. Could two MC be bad back to back?
I know I'm missing something. This is the forth Volvo for me starting with a '68 142S. I've done alot of brake work on Volvos and other vehicles, I'm almost out of ideas on this one. Sorry to bend your ear.
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