air getting into the system

after I rebuilt my brakes a few years ago they never seemed that firm. I put this down to the rear disks needing to bed in to the new pads. The brakes were always good enough to pass the MOT and avoid the odd idiot that tried to pull out in front of me. But after the last MOT they started to get excessive travel. So I bled the brakes just as a test and even though I was thinking the master cylinder (which was new) maybe a fault. After bleeding the rears the brakes came back better than ever, really firm and strong. Bleeding the fronts had little effect. So I think the rears are letting air in some where. Over the last few years every part of the brakes have been replaced, the previous owned had two reconditioned rear calipers put on too. I've order a set sills for all the calipers, front and rear and will refurbish but I was wondering if there is any other way air could be getting in? I can not see any leaking of fluid at all and the reservoir is not emptying over time, as you would expect with a leek.
 
Fluid can collect in the dust cover of the rear brakes. when you get them off it will be simple enough to tell if fluid has pasts the seal.

If this happens the fluid will be trapped and when the pedal is pressed there is no pressure on the piston.

Colin
 
If a braking system has been fully rebuilt and bled for the 1st time microscopic pockets of air remain in the system, over time these collect together to form bigger bubbles which leads to a spongy peddle - so no air getting in just collecting together.

You may find you have fixed the problem altogether.
 
Hello Richard,

Have you noticed if there is drop in the fluid level within the reservoir over time?

Ron.
 
No perceivable drop in the fluid level which makes me think it's only just started and I've had to bleed them rears a second time as the peddle travel returned. The fluid that comes out at first when bleeding looks like it's been whipped, loads of micro air bubbles in it. The new seals should come today so I can replace them and see if that fixes it.
 
No perceivable drop in the fluid level which makes me think it's only just started and I've had to bleed them rears a second time as the peddle travel returned. The fluid that comes out at first when bleeding looks like it's been whipped, loads of micro air bubbles in it. The new seals should come today so I can replace them and see if that fixes it.
 
I've stripped the rear calipers off to day and rebuilt them, just have to refit tomorrow. Was a very easy job getting them off. One of them was leaking but as the brake cylinder is inside the the hosing it can leak, as one of mine was, without you ever knowing. the other caliper is a recon unit but still the cylinder whilst not leaking was a little stuck in there, so I replaced it's sill too. I'll post up the pictures when it's all done.
 
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