Assuming the system isn't leaking anywhere, such as at the banjo bolt attaching the brake hose to the caliper (did you put a copper washer on both sides of the hose attachment?), And barring any master cylinder failure, the only way you could still be getting excessive pedal travel would be excessive travel in one or both of the caliper pistons. Double-check correct pads for the application (sometimes can be more than once size brakes for the same model, although I think these vans just have one size), proper thickness of rotor and that it's properly seated before bleeding, also that both calipers are correctly installed on steering knuckle.
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Monday, June 7th, 2010 AT 11:42 AM