I am almost at my wits end with my brakes. Ive had both of these issues for a while, I rebuild the calipers, got new rotors, changed pads, rebuild master cylinder, have SS lines, have bled the brakes countless times and my brake pedal is still soft. If I want a strong pedal feel I have to double pump the brake and it will feel very stiff.
I have also tried bedding in pads before and got that brake judder, so this time I didn't bed them in and driving around town it was fine but last night I was on a mountain drive and after getting the brakes hot, 60+ mph braking had tons of pedal and wheel vibration but was fine at slower speeds. I have no idea why I constantly have these issues even after buying quality parts and doing everything right, it is making me seriously not enjoy my car anymore.

 

One of the guys on here had a similar issues with his brakes being soft after a whole overhaul with new aftermarket parts and it ended up being the titanium shims they were slightly bent or mis shaped and flexing every time the pedal was pressed. Not sure if you're running any pad shims but just throwing that out there. @kyoo can maybe chime in and give some insight.

 

reliving my nightmare here lol.

OP, what shims & pads?

 

bad bushings/ball joint will also cause "judder" on braking.

I spent a lot of money and time chasing down what I thought was a brake related problem. After doing pretty much everything as you have, I changed the bushings and ball joints on the front Lower control arms and problem solved. Of course this might not be your problem, but IMO worth looking into.

 

Its funny because I read your thread but I don't even run shims

 

I have the Whiteline bumpsteer kit so its new bushings. I have read a little about wheel bearings causing brake issues? but I don't have a those symptoms really

 

give us a little more specs and history. have you tried engaging abs between bleeds?

 

Yes, and I have bled after and no significant bubbles or anything. When I really think about it, I always had kind of a soft pedal but this issue of literally having to double pump my brake if I want to get any stopping power came after rebuilding my calipers. That first brake stomp has also no feel but if I pump it immediately after I have the most stiff, direct pedal feel and my car will stop.

 

I'm having literally the same exact issue as you are after rebuilding my calipers and adding stainless flex sections. Initial push of the pedal is spongy and has maybe an inch or 2 of travel before getting any pressure, then if I let off and reapply, it's much more firm like it should be. Prior to this the brakes were spot-on. I've bled them probably 3-4 times and still haven't gotten anywhere. No leaks either.

 

I noticed both of you rebuilt your calipers...did you also get them powder coated as well? If you did were the calipers split when they got powder coated? I haven't read it on here but when I used to frequent the Subaru forums some people had issues with spongy brakes after they got their calipers split then powder coated. Might have something to do with it? When I was getting my wheels refinished at the powder coating place I asked for a caliper quote along with rebuild the owner mentioned that he doesn't split the calipers ever. Not sure the reason but maybe this has something to do with it?

Hopefully you guys can get this figured out...do you guys have any evo buddies willing to let you swap calipers for testing?

 

I painted the calipers and rebuild myself, never split them

 

Mine were powder coated but not split. I will say that I haven't tried to bleed any air from the ABS unit though..

 

mine were split and powdercoated personally, but i haven't noticed softness in that regard

 

Random Update- brake pedal all of the sudden is responsive again but now every time I let off the brake I hear a squeak sound. I don’t know if the caliper piston is sticking or if the pad is dragging

 

Check brake pad wear. They may be just worn enough for the squealer to touch the rotor.