My brakes are driving me mad and I'm running out of ideas, running out of brake fluid, and running out of time to fix this SOB (need it for some volunteer work this weekend). Any ideas appreciated!
This all started recently when my passenger's front caliper started sticking. I replaced both front calipers with remans, figuring if one was giving me trouble, the other probably wasn't far behind. I put them in, bled them, and the brakes were mushy. They would stop the truck, but with the engine running, I could bottom out the pedal. Pumping didn't raise the pedal. Bleeders are on top like they should be and brake fluid comes out clear from all four corners and the ABS valve. I noticed that my master cylinder was leaking out the weep hole and thought, hey, I'll bet these two problems are related.
I bought a Beck-Arnley MC. It came with no instructions or bleed plugs, and after a whole lot of screwing around, all I managed to make it do was lock up the prop valve somehow to where fluid wouldn't come out the rear port even with both fronts plugged and my foot on the pedal. That ain't right.
I sent that junk back and ordered a Dorman MC. Came with instructions and plugs, bled properly on the bench, got it down to the 1/8" free travel specified in the instructions. Put it in, hooked it up, did a little bleeding. Pedal felt mushy like before. Bled a bunch at the calipers, the ABS module, and where the fittings meet the master. Zero change. It'll lock up the front brakes on dirt, but with the engine running, I can bottom out the pedal with very little effort. I adjusted the push rod between the pedal and the master, no change there either (not like that's what caused the problem in the first place).
If I remove all three lines from the master and replace the bleed plugs, the pedal is hard as a rock. Clearly the master's not the problem.
I tried plugging one port at a time, thinking I'd find the one line with air in it. Mushy each time. I blocked the rear and passenger's front ports and tried just the driver's front, thinking I'd start with the shortest line, and of course it was mushy. Bled it at the master (propped the pedal and cracked the fitting until air quit coming out), bled at the caliper. Still mushy. I have no idea where air would hide in that line. Maybe the caliper pistons are retracting too far? I'm really running out of ideas here.