Spongy brake pedal after new front brake installation

I just installed some steel front brake lines and 5th gen 4runner calipers, pads, and rotors (all new parts) on my 2011 DCLB with OME lift, ARB bumper/winch, 255/80/17s, and Leer canopy. My pedal is super spongy now. I bled the brakes until no air was coming out, drove a few miles and bedded them, came home and bled them again, getting a little more air out. I topped the master cylinder off and drove it down the street and back and it felt a little better.

I drove it about 6 miles to work this morning and it was still spongy. Thinking there might still be air in the line, and working across the parking lot from a shop, I had them do a full brake fluid flush on it. They commented that the brake fluid level was low when I picked it up. It was still the same pedal-wise when I drove it home.

When I push the pedal, it takes longer to start doing anything. I have to push it down at least twice as far as I used to before I feel any slowing. If I continue with slow pressure, it goes all the way to the floor with some resistance, but it's spongy all the way down and doesn't give the increasing resistance like it did before. If I hit them hard, it stops OK, but I don't have a ton of confidence in the system overall. I looked under it for obvious leaks when I got home but it was dark and raining so I couldn't tell much.

I'm highly suspicious I have a leak and am going to look into it tomorrow after work. If the brake fluid is low again in the morning then I guess that's my answer. But before I drive myself crazy looking for a leak, is it possible/likely that the new caliper is throwing off the proportioning valve? I don't read of people typically changing it or the master cylinder with this upgrade. Any other thoughts except "Find the leak"?

 

Oh, and at what point would one expect the brake light to come on with a leak?

 

Probably small leak by the caliper is my guess.
I accidentally opened my brake line once doing a brake job, my truck was on jack stands for a week in the middle of my college campus. Funny thing was, no once said anything, I guess everyone knew it was me and figured I was just a nut.

 

Brake lights shouldn't be affected I believe, at least it wasn't on my grand Marquis

 

I meant the dash warning light.

 

Oh, I don't think ever. Mine never did when I let tons of air in the system. Not actually sure what that light does, maybe abs sensors or something. Don't quote me though.

 

First look for leaks if you are continuously loosing fluid.
If you are loosing fluid to the point of being low in the reservoir it’s likely a leak.
How much fluid did you loose doing the swap?
If the reservoir became empty and air made it to the ABS Modulator you may need a shop to bleed them for you. As far as I know, there isn’t a good or easy way to preform this with out a good bidirectional scan tool. I would not recommend using the “jumper” method to activate the pump. If you leave it on too long it can get expensive quick.

But hopefully it’s just a leak.
I don’t think you have a big problem.
It’s probably a leak or air in the system.