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my truck had this prob while i was driving it(currently down for body swap) everthing has been replaced on my brakes and i mean everything! i felt stupid when a buddy of mine who is a ford mechanic told me i need to adjust my rear brakes bc too much of the stopping is being done by the front brakes causing the fluid to overheat and reduce brake performance. havent tried it yet bc i have bigger fish to fry at hte moment but it may work for you. and best its a free thing to try! so i say give it a go.
ps let me know if it helps you out.
I've read that you checked the piston in the caliper and it moves freely but does the caliper itself slide on the caliper bracket?
Does the brake pads look wore more on one side of the rotor than the other?
New calipers are pretty cheap so I would advise against rebuilding or trying to lube them up.
The other thing that comes to mind is that you have water in your brake fluid that is boiling causing pressure to build up in the lines. However if you are using fluid from a new container to replace the fluid you are losing when you bleed the brakes and replaced the lines this shouldn't be a problem
I have not checked the rod length, however they work until they get warmed up. The pads look good and even. The calipers move freely on brackets. I am going to try new calipers. I don't know if there is water in the lines, but I will flush the system out.
Personally, I like to locate the problem before I buy the parts.
When you say “it happens went the brakes are warmed up” do you mean they will not lock up if you are sitting still and simply pump them, does it happen driving normally or does this only happen after stopping hard?
Note, I still think the prob is the MC not releasing pressure. This has happened to me twice, both times during normal driving and both times it was the MC(my bad). Incorect rod length was one of them.
After normal driving for say about 10 minutes or so. If I just sit and pump them it doesn't happen. I personally think it is the master as well. I am picking up a power brake booster and master cylinder from a guy to upgrade my system to power brakes, I know for a fact that his master is good.
I was looking up under the dash and it appears that the rod between the brake pedal and the master has been replaced, it is bright and clean cad. plated. I am wondering if someone changed the rod and put the wrong one in. How can I tell? My truck is a 1979 F-100 302ci with and automatic and manual brakes.
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