100 series pads on a 92?

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I see you bled it...did you flush it?

Also, get under there and listen for a whoosh by the booster.

Seems like you may have issues there.
 
Well, I emptied the resevoir, filled it back up and have bled ~ a pint from each corner. I would assume this would be enough and I've gone through over two quartz of fluid over the past week and a half but I'm open to suggestions.

I'll check the 'woosh' tonight. Thanks again Dan.
 
If you drained the reservoir completely did you then bench bleed the master cylinder?

If not, you just found your problem.
 
My truck was the same when I purchased it used. Did the usually brake job of pads and bleeding and it took care of it. You might have after market drap for pads. The low first push compared to the second would be air in the lines or pads well worn down to where the caliper pistons are extended quite close to the max.
 
I did not completely drain it. I left ~3mm standing in the bottom of the resevoir. The braking was worse before my saga so it is getting better. I used a bulb syringe as the original fluid was nasty looking. I'll look at it again but it appeared to be there was just one passage that lead down to the master and I never drained this piece and left just a bit in the bottom.

It is possible the PO did not bleed the master as it was recently replaced. Personally, I've never had an issue with the master cylinder in a horizontally mounted unit and bleeding them individually usually caused me more problems than it fixed. Disconnecting the brake lines from the master and reconnecting them causes a nice bubble that has to be bled clear to the brakes.

http://www.vtr.org/maintain/brake-bench-bleeding.html
https://forum.ih8mud.com/index.php?board=1;action=display;threadid=8413;start=msg71822#msg71822

On the pump up theory, I only get an improvement on the second push but not on subsequent pushes. I may have a bit of air but it's fairly minor. I attributed it to engagement distance rather than air in the lines. I'll do a bit more research once I get home. Thanks all for the ideas!
 
Checked the booster. No leaks. No noise from the master although I can just make out a noise when the brake is depressed. Too much engine noise to hear anything with the engine running.

Interesting idea on the runout. It's on my list but have not gotten to it yet.
 
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