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We took the car to a Volvo dealer that we sometimes use for repairs to have them diagnose the low brake pedal problem. They inspected the brake system and found nothing obviously wrong, so they recommended another attempt at bleeding the system again. I told them up front that I thought they would be wasting their time since the brake lines had been bled to death already, but they insisted saying that they had to start somewhere to find the problem.
So they bled the brakes again with no change in the pedal like I had predicted. They brought many experienced Volvo mechanics together to determine what to do next. Some of these mechanics have 30 years of Volvo experience. Their analysis pointed back to the rebuilt front calipers. They said if the caliper cyliners were not bored evenly or correctly that it could cause the problem that I'm having. They wanted $600 to install Volvo OEM calipers on the front and said they would take them back off again if the problem wasn't solved, but I would be charged for two hours labor. Since they have to order the calipers, I opted to hold off spending another $600 until I found out what my options were.
The Volvo dealer did not charge me for bleeding the brakes again. They only charged me for 1/2 hour labor which I thought was a fair deal given the time they had spent working on the car.
So off I went from the Volvo dealer to Carquest auto parts to take back the second master cylinder and to speak to the manager about my dilemma. He said that I could file a claim to get back some of the labor charges that I had paid the independent Volvo repair shop to replace the faulty master cylinder. Since he has a working relationship with the independent Volvo repair shop, he asked me to take the car back to them for repair. He said that if the rebuilt calipers were bad after all, he would work with the repair shop to replace them under the warranty program so that I would not have to buy and return more parts to the store. He also said he would cover the front brake lines if they were defective. So the car is back at the independent Volvo repair shop that replaced the master cylinder for further analysis and repair. The shop feels they will find out what the real problem is this time around.
We'll see what happens now.... I'll post back when they finally fix this mess.
DeWayne
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