Can't get brakes working after repair - 92 S4

[Dan Smisko]

I've just completed a brake repair on my 1992 S4.  It turned into a
caliper overhaul.  The initial problem was a rear pad that jammed and
scored the rotor.  Then I found torn slider boots and piston boots.
Some moron left the caps off the front bleeder bolts and they were
really rusty.  And the front rotors were too low to turn.

So I replaced all rotors and boots and seals and front bleeders.
Also replaced the bomb with one from a V8 that I think is good,
but not certain.  Mine was leaking down a lot just sitting at work.

Did the "pre-bleed" on the rears, per Bentley, but ran fluid into
the hose and out the bleeder, rather than their "reverse" direction.

Now I can't get the brakes bled, or so it seems.  The pedal goes
to the floor with little resistance.  When this happens, the brake
light comes on for a second, then goes off.  I'm using a pressure
bleeder, and did jam the stick in the spring on the equalizing
valve, or whatever it's called.  So far a couple of liters of fluid
have gone through with no improvement.  It's coming out pretty clean,
though.  :-)

Any ideas?  Soon I will have to admit ignominious defeat and have
it towed to the shop.

Also, does anybody have a pad connector for the wear sensor?  Or know
where I can get one?  The ones that came with the new pads don't
fit, so I had to splice in the old ones.  The one on the right has
a broken wire right near the connector.

Thanks.


Dan Smisko