he discovered that even at 10 MPH, when he applied the brake pedal, the rears would lock up and the fronts didn't work!!! Not the best timing, since we were heading out of town for a wedding, and it would have to sit until we got back.
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Had this problem. After fluid is low u need to bleed brakes with prop.valve boot tool. Ore rear'll lock first.

 

Thanks for the information Pablo!! I had the same thought, but wasn't sure I was correct.

I took the van out last night for a test drive myself and going 45-50 MPH on a local dirt road (I didn't want to squeal tires on pavement!) I jammed on the brakes hard to see what would happen. It stopped nice and quick but no rock throwing--seemed pretty normal to me. I think maybe the ABS system prevented the wheels from "locking up" on hard stops. I suppose in a true "slam on the brakes" emergency, I will find out then if I can get the tires to "squeal" to a stop!!

It seems to brake normally now, so I'm going to be cautious for the first few days I'm driving it around town running errands. DH is just really worried and trying to be cautious due to me being pregnant and driving around with our daughter in the back in a van repaired by him.

I have to tell you guys though, DH was able to rent the tool at Autozone and only messed up the first line he tried to bend. He had to go out and buy another line at local parts store for $3, but was able to do it right the second time!!

The real kicker was after he installed the line and was ready to bleed the brakes--the bleeder valve was so rusted on the caliper, he snapped it off!!! So off to the parts store to get a new caliper for the drivers side!! Then when he wanted to bleed the passenger side, the same thing happened again--the bleeder valves snapped off!!! I bet you can imagine the language he wanted to use That is mainly why this project took him so long!!! Plus having to do more than he planned on what seemed to be a "simple fix" almost has made him swear off of auto repair forever!!! But I know he is proud that he was able to do it himself.

 

delete.....

 

heavily rusted bleeder screws are a good indicator of time to replace the calipers anyway, pistons and seals shot also

good front brakes are critical in getting one of these nose heavy vans stopped
he made the van safer for you and the girls

any man can bend and make brake lines, few product good babies especially 2 sweet girls and then stick around to love and take care of them

 

Thanks 96_4wdr!!! Although it might have been time to replace them, DH was not happy about it!! Oh well, too bad--so sad!! Although, having the front wheels off gave him a really good look at that rack and pinion that Aero is due for....and he's already grumbling about it...

 

he'll earn his room and board and a spot in that warm cowgirl bed after replacing the rack in an AWD Aero

 

Oh, I'm sure he will be due for a really nice dinner and massage after that particular repair is finished...

 

I recoomend to replace calipers on both the front wheels. Onse caliper on semitrailer of our company was not replaced in time, it was stuck and on hightway one disk was overheated, burned tire, tire burned goods in semytarailer and we had to rebuild all the semitrailer.....

 

A good tip is to install bleed valves with brake grease like Lockeed, Bendix or everything else, that's a good insurance for future mechanic.

 

i know its a bit late but....

thats actually exactly OPPOSITE of what should be done. always follow the procedure in the manual, IF available.

or the FURTHEST from the MC first. the closest should be dead last.