I acquired this '94 944T last summmer. Even then the brake pedal was soft/spongy. The front pads and rotors were a few months old at time of purchase, and I replaced the rear pads and rotors, and completely bled the system (using EZ Bleed tool from IPD) shortly after taking posession. The pedal feel did not improve much after that.

Now that the weather's turned colder I believe the pedal travel has increased. The braking performance is fine once engaged, and nothing appears to be pulling. Wheels spin freely when on the jack. This past weekend I bled the lines again (some bubbles were present), and also verified that I had no bulging flex lines during braking. There is no evidence of weeping bleed screws. If one gives the pedal a quick double-pump the feel is good and pressure is maintained.

I'm thinking the only thing left to replace is the master cylinder.

Anything else I should try as well?

Thanks!
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'94 945t

The question is, "soft" vs what?

The ABS pedals seem to be pretty soft vs the older non-ABS Volvo's.

Does the pedal firm up with the car off, and the brake servo vacuum used up?

Does the pedal go to the floor eventtually if you stand on it for a while?

-Ryan
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Athens, Ohio
1987 245 DL 324k, Dog-mobile, E-codes
1990 245 DL 137k M47, E-codes, GT Sway Bars, GT Braces, Dracos
1990 744GLE 189K 16-valve project
1991 745 GL 304k, Regina, 23/21mm Turbo Sway Bars

Soft, as in excessive travel before the brakes apply.

Compared to what? I have another 940 from the same year. I always felt it had a soft pedal, but the car in question is much worse.

Gold standard for my comparisons? That would be the wife's 2005 S80: about 1/4" of pedal travel and your face is against the windshield. A lot of that may have to do with the larger rotor diameter on a S80 vs. 940, so I don't expect to reach that. But it would be nice to be able to apply the pedal without the sensation that the floor is approaching.

The pedal does firm up with the motor off, and it holds its position well upon reaching that point.

So knowing all that what is your diagnosis?
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'94 945t

Your description sounds like a classic case of a bad master cyl.
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David Hunter

Hi,

Mine does that every time one of the calipers gets frozen, with rust.

Gus

I've had soft pedal symptoms caused by a dragging (but not completely seized) piston in a rear caliper. Check for uneven pad wear, and compare the force needed to retract the pistons.

Good luck!

Is it worse after you drive around a few corners, not so noticeable if you have only driven a short distance in a straight line?

If so, look for bad wheel bearings. Look particularly for lateral movement on the back, where you might not notice it.

No, it's equally bad at all speeds, including 0 mph.
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'94 945t