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I had a lot of travel in the pedal before brakes would engage so I knew I had to bleed the system. I flushed and power bled the entire system and did the manual ABS activation and bled again. Made a huge difference.
Now, 2500 miles later, I’m getting the spongy pedal again. Fluid is still full, pads have plenty of life. Not sure what to focus on next? Any advice appreciated.
I'd look for line leaks, check the flexible hoses very closely, and check the calipers for leaks or issues. Being in the northeast, I would inspect each caliper closely for leaking and corrosion as the bores can get really gross, especially if brake fluid is not regularly maintained.
If no leaks and everything looks good, maybe a master cylinder issue? You could try dead-heading the MC with some plugs but I've never done it, so I couldn't walk you through it.
When you say "power bleed", did you use a pressure bleeder on the MC? I have heard this can introduce air into the system, but no experience with it. I used a couple of expensive vacuum bleeders, didn't work, and got very frustrated with them.
Many people disagree with me, but good old gravity bleeding works. It has been the only method I have found that seems to work over many car brands. It takes time, patience, a lot of clean fluid, and a couple cheapo bleeder kits, but it can be done. I have used this method on my Fords, old squares, Honda CRV (more than I care to remember), and wife's VWs. Works for regular maintenance too.
Bled the whole system again. Had more air bubbles somehow. Brakes are functioning fine now but wondering how more at could have entered the system. Fluid level never dropped. Will update after I put some more miles on. Thanks to all who replied.
I am wondering if there is an issue inside the MC. Bad seal internally maybe? That might be able introduce air without fluid loss. If you cannot find a leak elsewhere and fluid level isn't dropping, air has to be getting in someway.
Where did you find the air or did you have air at every wheel? Brake fluid attracts moisture and that moisture can be rough on the cast items in a brake system. If there is pitting in any surface a seal rides on it can introduce air into the system.
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