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OK I have seen this on here a couple of times and no one seems to have directly answered with the solution. I have a 94 f350. Just changed out the calipers, pads, lines and converted rear drums to disc's. I have bled the system 20 times. I have a rock hard pedal when the truck is off...as soon as I start it the pedal goes to the floor. I replaced the master cyl. today even though the old one worked fine before, then this evening I replaced the booter....still the same problem. I have seen several posts where people have had a similar problem but no body has posted what fixed it....any ideas.
PS....no leaks that I can see...or hear...system has been bled well...like I mentioned earlier rock hard pedal when its off.
I changed the rubber the lines with new ones. I talked to a guy at the ford dealer and he said the new parts could have increased the pressure in the system enough to cause the ABS unit to malfunction (if the units valves are weak) and he thinks the fluid is getting dumped into the ABS unit. I am going to try and bypass the unit all together and see if that fixes it...it is easier to do that than spend $200 on a new ABS unit.
I have done dozens of brake jobs and this one really has me perplexed.
I don't know if it's possible on your application, but I know a guy that put the calipers(this was on front brakes of a dodge) on the wrong side and it put the bleeder in wrong position. It wasn't at the highest point of the caliper, so he couldn't get all the air out.
I'd appreciate hearing what you find out about that ABS valve. I got much the same problem - no leaks, all bled out, but the pedal acts like there is a leak - some of the time. I replaced the master cylinder and was quite surprised to find that didnt' change the pedal behavior a bit.
Oh - 1997 F250, RABS...
Are those ABS valves available aftermarket, or is that just a dealer part? Mine is a solid block of crusty, rusty crap...