More thoughts on your brake problem. First, the aforementioned ridges tend to move the pad away from the disk (particularly while driving) further than normal, cocking it a bit. This is normal and will require extra pedal travel to move the pads in until they conform to the disc. Unfortunatelly, the use of the parts of the master brake cylinder which normally don't get used can be bad news, particularly if the fluid had not been changed every two years as Volvo recommends. The moisture which brake fluid naturally collects can cause rust at the limits of pedal travel, and could be part of the problem. Let us know how the test suggested by NOv8or comes out.
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