I have a 2003 f250 and the brakes will stick from time to time. I have since replaced all 4 pads, rotors, calipers, all flexible lines, old fluid, shortened rod going into MC, and nothing seems to work. I cant tell if it is all 4 corners or just the front. A few times the front brakes would be smoking, but after i replaced the calipers and fluid it hasn't locked up as bad. When the brakes start sticking i can tell because there is NO pedal travel. It does it hot or cold seemingly completely at random about once a week. As soon as i put it in park it unlocks and i cant see whats holding. It has me and my mechanic stumped. Besides the master cylinder is there anything that can be holding pressure on a 5.4 with ABS? I would realy appreciate any advice!

 

Have you replaced the break caliper pins?

 

Let's say one of the caliper pins is stuck. I would think you would have noticiably unbalanced braking, not to mention a hot wheel. What could it be, besides the master cylinder not releasing pressure?

 

Maybe the vacuum booster or the lines from the engine to the booster? That's where I'd look. That's really suspicious when they release after you put it in park.

 

The calipers came with new pins besides i thought it would be a wierd coincidence that both sides locked up at the exact same time. I have not thought about the booster but it does make sense that the pedal would loose all its travel. Would there be any valves for the abs that would freeze up or does it only release the pressure when engaged?

 

Took it to the dealer. They seem to think it is the abs hydraulic controler locking the brakes. They want to test it when it is locked up before they replace it but it wont stay locked. The problem is the unit costs $900 just for the part. I dont need abs so is there a way to delete the whole system and bypass the controller? I looked at getting the parts for an earlier truck with rabs only but it would end up costing more. Just want to get it fixed before school starts. Thanks

 

Master cylinder will cause this problem as well. Cheaper and easy to check.