My el cheapo 2001 TJ is running like a champion, my 4X more expensive and newer 2004 TL is being a real biatch.

When I got it, brakes felt spongy.
Bled them, some air, felt better.

12 months later, brakes felt spongy again. As before, I can press lightly, and feel the pads (front?) engage, but the pedal goes down much further before the others (rears?) engage.

Bleed it again, put new pads in, a bit better as far as the two step engagement goes.

One week later, it's back.

From past experience (Sigma) a badly sealing rubber cup in the master cylinder can let air in when you release the brake pedal, and no amount of bleeding will fix it.

So, master cylinder overhaul time.
I'm going to grab one from the wreckers (one with fluid still in it) and rekit that, then swap over. Minimal off-the-road-time that way.

So, questions:
Who (and how much) has the rebuild kits?
What is the best way to bleed a new master cylinder on an ABS equipped Magna, without getting air into the ABS unit?

Best I can figure, is no.
Not unless you can do it submerged in brake fluid! LOL.

If you are good, you may be able to get the small bubbles to come back up through the master by squeezing the calipers to force fluid backwards through the system. This does risk trapping air in the master if you can't get enough fluid flowing back.

Best option I can figure, otherwise your stuck having to bleed the ABS.
With that, I have no experience or advice...

Just bleed as normal, no need to worry about ABS

I have come across a few magnas over the years like this, usually is the boister

MR906267 CYLINDER KIT,BRAKE MASTER
http://www.amayama.com/search/?q=MR906267

Complete aftermarket B227-064
http://www.ebay.com.au/itm/Mitsubishi-Magna-TL-2003-2004-Master-Cylinder-Assembly-B227-064-/271262171434

Major Kit K8674 (protex) out of ATAP catalogue http://www.oziautoparts.com.au/hydraulic-cylinder-repair-kit-part-no-k8674/

I've ordered from Amayama but I always check local prices and the part numbers first with a dealer, occasionally the prices are ok but it's rare.

I'd expect MITSFIX would have a few master cylinders out of the TL/TW.

I've never liked the brake feel in my TW, always feels spongy because of the pedal pressure i have to apply but I have had issues with siezed guide pins and rotors badly glazed with the original pads. has improved with freeing the calipers up, new rotors and pads but it's a very heavy vehicle + auto for the std brakes to pull up. it's one of those things i wish they had upgraded with twin pots and larger rotors but i think these go back to the TR/TS generation size wise.

i know with a V6 TR I had the biggest improvement I had with that was after new rotors and bendix Advance pads which were dusty but bit really well but that's a long time ago now.

Great to get this info, thanks guys!