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I have a 1997 F250LD 4WD. I was driving and came to a stop light. I hit the brakes and the pedal was rock hard with what seemed to be very little travel. I pushed hard to get to a stop and the abs activated and I came to a slow stop. This has happened about 3 times over the last 1000 miles of driving. I see no ABS or Engine lights. Most of the time the brakes are normal. Pads are fine, fluid is fine. Brake booster seems to work fine, pedal is not mushy or hard to press other than the 3 or so times this has happened. Once this happens I can let off the brake and everything is normal. I have not found any vacuum leaks.
An important point is the ABS activating.
It normally does not unless a wheel loses traction under braking conditions.
I think the ABS system is the first suspect.
You can't lock up the front wheel unless you can put enough pressure from brake application.
If it goes hard, that application 'normally' can't be done.
Otherwise hard pedal is a loss of vacuum.
If the pedal was hard on a first application it's not the loss of vacuum unless the booster is faulty because you normally have enough vacuum reserve for a second application before it is used up. .
Granted, these are opinions but based on the (2) systems inter operations.
Good luck.
So you have front wheel speed sensors?
If you have a bad wheel bearing it can *sometimes* cause the tone ring to move out of alignment with the wheel speed sensor. The ABS would interpret the missing wheel speed sensor signal with the BOO switch on as a need for the ABS.
Can your scan tool read chassis codes?
Would the chassis codes (missing wheel sensor) be stored even though there is no warning lights on? I dont have a scan tool but local parts places do and will scan for free.