Gentlemen, I have shadetreed many brakes over the years and was never stumped like this.......Please help if you can....I got to get this on the road without paying a mechanic!!!!

99 expedition. I changed the left side rotor and caliper.

I changed the right side rotor. I did disconnect the caliper and removed it. I was going to put a dust cover seal kit on it....but no one had one in stock so I put the old one back on. It was a bit more difficult than a ithough it should be and it might be that pistonis jammed by this seal. I doubt....but maybe? so mounteed everything and poured in fluid. Seemed about as much as drained out. I have bleed each wheel several times. I have tapped on both calipers with a rachet, and a deadblow hammer to possibly displaced the tiny bubbles that may be clinging to the inner walls!!!

All I have ever gotten out of the pedal upon start up was all the way to the floor and never pumped up. When it is not running teh pedal goes to the floor the first time and then pumps up to a fairly normal position as it always did? WHAT IS UP???? Master cyclinder? Please don't tell me to keep bleeding! If this piston is stuck....would that cause my symptoms. I'm going to remove it again tomorrow and take off that dust seal just to see if all get well. I'd appreciate any ideas. I'd REALLY appreciate the solution!!! Sorry for the longwindedness of this thread, but I got to have some relief~~~~

 

I would think Master Cyl since the pedal goes to the floor and bleeding hasn't restore a good firm pedal. Air will cause a soft pedal, and even then you would have some pedal after pumping. Master is full? All bleeders are tight? Leaks anywhere?

 

Nope, it was the incorrect caliper I put on before I notcied that the bleeder was on the bottom instead of the top....duh. Apparently as far as I can tell the calipers are identical except for the position of the bleeder. That is all that determines left from right. Makes perfect sense I guess. All you have to do is look at it BEFORE you put it on and you will see if it's for the correct side. That way no panic and ranting to the Ford Forum is required!!!

Got it together today and all is well.

 

LOL recently had a late 70s Corvette brought to me with the same exact problem !!! the car had all new 4 piston calipers installed by the owner and he put all the calipers on the wrong sides!! needless to say he would have spent an eternity trying to get brakes to work on that car.... glad you found the problem before we started throwing reccomendations at you as that is usually that last thing anyone would ask when trying to help diagnose your problem.......