You guys have helped me so much with this van, I come to the experts once again. A couple years ago I noticed the pedal getting a tad soft but knew it wasn't so bad so I put it out of my mind. Well the last few weeks things have gone from slightly bad to very bad. I don't see signs of leaks anywhere and the MC has fluid. I saw a thread where a dude said you can take the MC off the booster and adjust some kind of rod and get your pedal back to normal but IDK if that will work for me.

For what its worth, the pedal does NOT stiffen up when you pump it a bunch of times. You know how it will normally get really hard when you pump it (lmao thats what she said) well this one needs some serious viagra. Where do I begin?

 

Soft pedal usually indicates air in the system. Air compresses, brake fluid doesn't. If no fluid loss, next thing would be to bleed the system.
I've also heard of soft brake lines expanding under pressure, but never experienced it myself.

 

In addition to rubber hoses expanding under pressure, the master cylinder bypassing internally could cause a spongy pedal. I am leaning toward the master cylinder being the problem.

 

Ok so I got the new MC and immediately i notice it does NOT have the threaded hole on top for what I think is the cruise control sensor switch thing. My cruise control on this van hasn't worked in years and I don't care about it so can I just use this MC without hooking that thing up and be fine?

Also I'm seeing videos and threads regarding bleeding sequencing RR, LR, RF, LF is that correct for this van? One guy said "it depends where your ABS module is mounted". Well IDK where mine is.....

 

I would return it for the correct master cylinder.

It should be in the same place on a van and a pickup: on the driver’s side frame rail below your feet.

 

Does your booster hiss when brake applied?

 

Yes for sure. Noticed it for a while now.

 

Yes for sure. Noticed it for a while now

 

Try that first, mine had the same issues with a soft pedal, changed the master, brake lines, rabs unit adjusted the wheel cylinders etc and it was still soft, then I got curious about my booster hissing when applying the brakes, so I changed that, and my pedal went firm, I don't know if it leaks or what, all I know it worked better after changing out the booster.

 

Hissing is vacuum bypassing the plunger rod seal at the back of the booster. My '87 F150 does this, and has for years. Has a spongy/soft brake pedal. Started when hissing did, and has gotten worse with the hissing. Just too lazy to change it out. Listening to it today, it's needing to happen soon though.

 

I believe a 1994 Econoline came with both flavors of anti-lock brakes. RABS or 4WABS like the Bronco. So the correct answer really is "depends".

 

Well i got the whole booster off, and there was some small box in front of it, down low, on a bracket that needed to come off in order to get the booster out. Not sure if that was the ABS module or not.

 

Easy enough to figure out. Were there steel brake lines connected to it?

 

Got the new booster in place and secured its 4 bolts, but now when i go to reconnect the brake pedal i notice this. How do I fix this? I'm never good with wire stuff.....

 

Brake switch, you will have to strip the insulation back and try soldering back to the terminal.