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OK?
Given: Brake fluid has to go somewhere for the brake pedal to go down at all.
Usually (and I am not a brake guru) the fluid is compressed between the cylinder walls and the piston (2 in our Volvos) and has only the brake line to move into. Then it moves in the lines and reaches a piston in a caliper, and it moves that piston out. Pretty simple, you say? agreed.
So - it has to be going somewhere for your pedal symptom to occur. With a failing master cylinder, as we all know, it moves around the MC piston seals.
You have eliminated that possibility, and also the possibility of a visible leak somewhere in the system.
So what about an invisible leak? Brake fluid that gets sucked into the vacuum assist thing will end up in the intake manifold and burn off. Are you having to top up the MC often? There is a check valve in the vacuum line feeding the vacuum assist, so maybe it's not working perfectly? Can you remove that vacuum line and check inside for brake fluid? See it? Smell it?
Maybe another brickster will have a way to test that vacuum assist thing.
Hope this helps.
Good Luck,
Bob
:>)
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