Are you bleeding all four calipers in the order in the FAQ?

Definitely could be a bad caliper. There should be stamped "markings" on the back of each half of the caliper that line up.

Here's how we got the air out of the 1990 240's MC about an hour ago:

Rear end of the car higher than the front, pressure bleeder up to 10psi, girlfriend in car, I was the grease monkey. I opened each bleeder and girlfriend pumped the pedal three times (or so) and held it down on the last stroke while I closed the bleeder (this keeps air from getting sucked in as the pistons retact). The circuit that went completely dry previously had a "vibrating" feel to it until a bunch of bubbles came out.

I actually went at things by the 1970's 240 brake manual, all bleeders at one caliper then moved to the next.

Since you probably have ABS, if the ABS unit lost its fluid, it'll be tricky to get things bled. ABS cars also have a much softer pedal, so remember that. If you "have brakes" (though that's a very relative term), you could take a test run or two someplace safe.

-Ryan

-Ryan
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Athens, Ohio
1987 245 DL 314k, Dog-mobile
1990 245 DL 134k M47, E-codes, GT Sway Bars, GT Braces
1991 745 GL 300k, Regina, 23/21mm Turbo Sway Bars
Buckeye Volvo Club