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Sure sounds like you got air in the system again, and this time including the plumbing and MC.
One possibility is that the reservoir emptied during bleeding. However, you're sure it never emptied.
Another posibility is..... No, let me tell you what my wife did when she helped bleed the brakes.
She would pump the brakes up and hold pressure. I would crack the bleeder, and the pedal would drop. When the pedal hit bottom, she immediately released the pedal so the bleeder suuuucked air back into the caliper.
Over and over this happened -- I could not change her evil ways. We went through this drill about ten times until I fired her from the job.
No amount of retraining would help -- her brain was hard-wired to release the pedal when it hit the floor. (This is just like her pumping the gas pedal in her 740 to "prime" it for a cold start. No persuasion can change the habit, even though we've owned FI Volvos since '73. It's hopeless, I tell you, hopeless...)
So I have a stick with a groove in the top (to wedge under the steering wheel) and the right length to hold down the brake pedal. I pump-pump-pump and then wedge the stick and then open the bleeder.....
...and wife's outta the picture, fixing lunch or doing something useful.
--
Don Foster (near Cape Cod, MA)
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