I've got a 2000 Villager that is driving me nuts with a brake problem I can't seem to solve. It started with excessive pedal travel, nearly hitting the floor before you even felt the brakes begin to grab.

To make a long story short, this is what I have done so far (in order):

1 - Bleed brakes with Mighty Vac
2 - Replace rear shoes and adjust star wheels.
3 - Bleed again with Mighty Vac.
4 - Replaced rear wheel cylinders, as I noticed slight leak during shoe change.
5 - Bleed again with Motive Power Bleeder.
6 - Replaced Master Cylinder with new unit (not rebuilt). Bench bled and did whole system with Motive Power Bleeder again.

Front calipers were replaced several months before this problem due to one side locking up. Front pads are nearly new, plenty of meat left on them.

Do these vans require a dealer to bleed them due to the 4-wheel ABS? I thought the Motive would take care of that, but maybe it still needs an ABS bleed?

Pumping the pedal a couple of times brings it back to a normal position, which seems to indicate air - but I've bled the darn thing so many times I can't imagine air still being in there.

The other strange thing, is that after a drive of 250 - 300 miles non-stop on the freeway, I had no brakes at all getting off the freeway until I pumped them a few times. I stopped and felt all the wheels, nothing felt hot enough to have boiled any fluid - warm, but not hot.

Any ideas? I'm stumped.

Thanks!