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940 brakes have issue with pedal travel 900 1991

uid 6185's pic
posted by  blue940 on  Sun Nov 23 13:55 CST 2003
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last visit: Sat Oct 18 21:11 CST 2014
[RELATED]

Car: 91 940GL sedan with ABS. Girling single piston front calipers & ATE rear. 246K kms.

Problem: The brake pedal seems to have a lot of travel (about 2-3 inches) before the brakes actually apply. When the brakes do start to work it feels as though there is less braking power than there should be which means I have to push harder on the pedal to stop. Pedal also feels a little soft.
HOWEVER, if I push really hard (REALLY hard) on the pedal several times while the car is standing still the pedal firms up and the travel is reduced to about 1 inch before the brakes apply. The brakes also feel stronger. This will last for several days before the travel increases again.
I'm not convinced that air in the lines is the cause. I assume that no matter how hard I push the pedal it wouldn't firm up if there was air in the lines. The pedal does NOT sink to the floor so I'm guessing it's not the Master Cylinder. Had rebuilt Volvo calipers and hoses put on the front about 3 years ago. New hoses put on the back about 6 weeks ago along with new rotors and Volvo brake pads. Back calipers are original as far as I can tell.
Could this be some sort of adjustment problem? I know the calipers are self adjusting but is it possible they are sticking (especially the back ones)? I assume that flexing in the metal lines wouldn't be causing the problem. What else could be causing this problem? I don't know where to look.

thanks for any advice.

Brad






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