2006 S60 2.5T FWD Brake pedal too soft and spongy

[faroutman89]

Hello All,

I know this thread has been covered and I've been reading most of them but haven't really got a full grasp on the problem(s) that I am having. Background information on my ride: 2006 S60 2.5T FWD (106,500 miles.) So, I decided to redo all of my brakes this weekend, front and rear rotors and pads. I was able to do all of that, no problems at all as I have done many brake jobs before.

One thing that I also wanted to do was a complete brake fluid flush because I noticed that the color is very dirty looking and the car has over 100K miles. I used a pressure kit because it's the only way to go for a job like this. I pumped the pressure up to 20-22 psi, which is more than enough to flush the lines out. Right away, dirty old fluid comes out and replaced by new, fresh fluid. All four brake lines were flushed out and the reservoir filled to recommended level. I start the car, knowing that I have to pump brake pedal a few times to engage the pistons, I pumped and pumped and pumped.

Problem is the pedal is too soft and almost touch the floor. What is going on? I was really careful not to let air into the lines as I know this can cause soft pedal. Also, the caliper springs are installed correctly as others on this forum have said that if it is installed incorrectly, it could lead to soft pedal. If anyone here can shed some light on this, I absolutely welcome it. Thanks in advanced.

[JRL]

They're not bled correctly, you still have air in the system.
Find a helper and bleed them the old fashioned way, (I'm leery of those one person DWI pumps).
Only about three weeks ago my mechanic installed new ceramic pads. Now I know exactly how these feel on Volvos and I knew they weren't 100% so I asked him to come over and we could do them together.
Instantly better and now they feel like they should.

[faroutman89]

I'm kinda thinking that there is air in the system, somehow. The kit is air tight but I have to say, I'm leaning towards doing it the 'old fashioned' way! I need to pick up some more fluid tomorrow. I will keep you guys informed as to results.

[vtl]

I do brakes alone, using bleed kit (don't like to share my beer... Jocking . Just redo your work in the right order: right-rear, left-front, left-rear, right-front AND use a stick to depress brake pedal throughout the bleeding - just push it against seat cushion. If it is still spongy, you may have a problem with master cylinder.

[faroutman89]

Ughhh! After a second and third bleed, now I know why my pedal was soft and spongy! Wasn't air in the line at all! The bleeder valve has a slow leak in the rear driver's side caliper. Not the bleeder nipple but the stem. I wiggle it a little bit and noticed that small amount of fluid are trickling out. This is unbelievable! I've been slaving for almost two days and this is why pedals wasn't taking. Now, most likely the caliper needs to be replaced and another flush, yet again!

[vtl]

Are you talking about bleeder valve screw? https://www.fcpeuro.com/products/volvo- ... w-30665014

I replaced those in rear axle of wife's V70, they rusted out.

[faroutman89]

After looking at it again, I just realized that the bleeder valve screw is one piece design and from the picture at FCP Euro, that confirms my suspicions. I initially thought that the only thing that should move when you unscrew the bleeder valve is the hex nut but not so. The whole stem unscrew! The reason I was getting leakage was because I didn't tighten enough! I guess I didn't want to over torque and break the nipple. That was it! Just needed to torque it down a little more. Problem solved! Two days of frustrations and headaches, not to mention the time that I will never get back. Thank you guys for your help. It is always appreciated!

[vtl]

Getting more experienced is never a waste of time.