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2004 F250 SD, 4 dr cab, long bed, 60,000 mi, mostly highway.
After gas fill-up for trip, next day started truck to connect trailer, and the brake pedal goes to the floor. Checked all four corners for leak and under hood, but no sign of brake fluid; however, the fluid is dropping in the brake fluid reservoir. I topped it off, tested the brakes a little more, with no success.... pedal still goes to the floor, and the reservoir is 1/2 empty now.
Had to leave the truck in the driveway and take my car.
Never had any brake issues before with this vehicle. They have always been solid performers.
Could the master cylinder have failed that quickly? From one trip to the next? Any ideas where that much brake fluid is going to so quickly?
I just got home from the trip in which I should have used my truck, but had to take the car, and I'll start investigating this tomorrow.
Looked behind the master cylinder and found no leak. I walked through the brake lines again and started to see some wetness along the left frame rail. I then found the brake line which had ruptured due to rust. The same think happened to one of my Cadillacs. The long brake line running along the left frame rail has plastic clips which hold it in place. These clips hold moisture and eventually start to rust the OEM steel lines where they contact the clips. I was lucky the line failed in my driveway, and not on the highway.
See the pics.
Does anyone know the purpose of the top large line. The Brake line is the bottom rusted one, the fuel lines are the two middle stainless lines.
Brake line failure due to rust: bottom line Hole on the upper edge at the clip location. Looks like a fountain when the brake pedal is pressed. Brake line failure due to rust: bottom line
if you replace a section of brake line, do not use compression fittings. Brake lines use a double flare style fitting. You may have to rent a double flaring tool from one of the parts houses.
if you replace a section of brake line, do not use compression fittings. Brake lines use a double flare style fitting. You may have to rent a double flaring tool from one of the parts houses.
Excellent point.
I invested in a good flare tool a few years ago to keep my '94 Fleetwoods on the road. :-)
Question: Why aren't OEM brake lines made with stainless steel, as they are with the fuel lines? It seems like a valid safety issue to me. Just look at the pictures above of the 17 year old lines.
Had that happen...while driving to my in-laws to pick up my son (they would watch him while my wife and I worked). Ended up taking his truck home because mine got hauled off to a repair shop.
The next day, his Jasper 6.4 grenaded while turning a corner when I was headed to pick him up and get my truck back.
It was not a good weekend for me.
I hate doing brake lines. I CAN do them. I just hate them.
I checked with two brake line companies who make SS, pre-shaped brake lines, but they didn't have a set for my specific application. Finally went with RockAuto and steel lines. SS lines would have been nicer, but just couldn't wait. My F250 is down and I need it working ASAP. I'll take some extra steps to protect the new lines and they should last for the life of the vehicle. It took 17 years for the original brake line to fail.
So, has anyone replaced the long brake line to the rear wheels? Any tips or recommendations will be appreciated. The line runs along the inside left side frame rail, and goes behind the fuel tank. There is one hold down clip I am having trouble reaching beside the tank along the frame rail. There is no/very little room to get your fingers between the tank and the frame rail. I've been able to get the brake line off all the other clips.
I should wrap this thread up.....
I ordered the brake lines for the entire vehicle from Rockauto:
DORMAN 919244 (919-244) Brake Line Regular Inventory - Price $ 102.79.
This was for a F250 , 4 dr, long bed. Just wasn't long enough. I had to splice in a 17 inch section of brake line, in the middle straight section, to get the correct length. The fit was fairly good.
Buying the whole brake line set allowed me the parts for the rear wheels, which I replaced, and I have the rest of the lines whenever I need them.
I would go ahead and replace them all. Chances are the next one will fail soon. I had this trouble on a farm truck. All the lines were shot when one failed. Think about it, do you want one to fail while you are driving the truck?
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