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Alright this has been really making me mad so i need yalls help. I have 1996 f-150 with a 1978 F-150 front end. The calipers are from the 78, but the rotors, extended brake lines, and master cylinder are from the 96. after the swap i bled the system over and over myself and then i would get pressure in the pedal, but after about 10 seconds it was gone. So i took it to a local 4WD place called Extreme 4WD and asked them to check it out. they told me they got all the air out of the system and replaced 2 lines but were still having the same problem as me, the brakes wouldnt hold pressure. The master cylinder in new(rebuilt) so i dont thinks its that. So to anyone who has done a SAS or anyone who knows brakes, help me please!!!! I know brakes arent that complicated but im really getting frustrated. Could the different years of lines and calipers be the problem or maybe the 96 master cylinder isnt designed for those 78 calipers. I dont know. Mayb u guys could tell me what you did when you did your SAS. So any suggestions would really help.
Do these trucks have a bleeding plunger that needs to be held open when you're bleeding the brakes? I know my 77 did... right down on the driver's side frame rail, below the master cylinder.
beware that if the shaft from the brake pedal is corroded/pitted that it can tear the seals of a new unit; the shaft goes in much deeper than normal during the first few bleeds which causes the problem.
Been there.
Take a good lok at the master cylinder again, just because it is new doesn't mean it could not be bad.
If the system has been pressure bled and there is no air in the system, I would find the master cylinder suspect.
Make sure the rear brakes are well adjusted.
It's possible that because not all of the system is engineered to work together, mismatched years and parts, the master cylinder doesn't have the volume to operate the 78 calipers, (I know, it's a stretch)
Hope this helps a little.