[urq] Still no Brakes and Bomb test failed, now what?

[Maurits Jonkergouw]

I ask because the first thing I did was I changed the bomb and filled the ATF container to minimum, started the engine, locked the wheels 10 times (off ground) to bleed the steering rack and finally turned engine off, pressed pedal many times to watch the ATF level rise (emptying the bomb) and topped it until it reached 10-20mm from the top. When I ran the engine again the ATF level dropped again to half full, like it should. I assume there was enough fluid in the system for proper operation and any major changes in the fluid level would indicate serious leakage.

Now, after changing the Bomb and Proportioning Valve, rebuilding the Brake Master Cylinder seals, and a 20km drive with fully _better than ever_ operational brakes, it decided to go soft overnight and the initial problem has returned, grrrrr!

At this point, when the engine idles, the pedal goes straight to the bottom, when I drive the car and apply the brakes it feels very soft but pushing it down really hard stops the car 10%. If I quickly re-apply the brakes it will come to a full stop and the power assist is temp. back. Wait a few seconds and it's soft again, quickly apply, assist is back etc. etc.

When I shut the engine down, applying the brakes the first time, it goes to the floor, but not all the way. That last inch can only be pushed down with greater force. If I press it many times it feels good again but it never goes hard like it should (read bomb test). When I check the ATF level, I saw the initial level was half full, but press and hold the pedal down causes to raise the level by 10mm and if I let go, it drops 10mm again. Like I said, pumping the pedal many times does not cause the pedal go hard and most importantly, the ATF level refuses to rise.

(I know, too many questions for one thread, sorry)

Q1. If the rebuild BMC seals are leaking, could this result in unsuccessful emptying the bomb (per bomb test)? 

Q2. If the rebuild BMC seals are leaking, could this result in unsuccessful charging the bomb (per running engine)?

Q3. If the hydraulic system is not working properly, but the airless brake system is, the pedal should still feel firm when the engine is off?

Q4. If the pedal still feels soft when engine is off, there is likely to be air in the system, maybe because of the leaking BMC?

Q5. Is it absolutely neccesary the bench bleed the rebuild BMC prior installation, because I did not do this. 
See info here: http://www.misterfixit.com/brakbld1.htm

PS I bled the whole system 4 times (3x EZBleed & 1x classic w/assistant) and the last time (classic) the last FL caliper kept showing air.

I'm sorry, but this particular problem with my car is killing me.

Thanks again for any future comment or suggestion, how difficult it must be for you to answer the many questions because you simply cannot look at the car.

Regards,
Maurits

1986 GV (Swiss WR)
1985 CGT KV
1982 GL DD