Ken,

I expect that the problem lies in the master cylinder. If you were replacing the cylinder it would require "bench bleeding". I expect that somehow the system is not bled correctly.

Good luck,

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Larry Bible
'01 C Class, Six Speed
'84 Euro 240D, manual, 533K miles
'88 300E 5 Speed
'81 300D Daughter's Car
Over 800,000 miles in
Mercedes automobiles