2nd Gen Non-Engine/Transmission Brake Troubles

[DMcQuown]

Having an unusual problem with the brakes on a '99 2500 CTD. One day shortly ago, I nearly was involved in an accident when a car pulled out in front of me. I stomped on the brake and Wooosh, to the floor. Escaping a accident with the help of a roadside ditch, i find the brake lines between the fuel tank and the frame of the truck had rusted to pieces and blown. I replaced the brake lines, a rear wheel cylinder and decideded to do both front brakes/rotors.

While bleeding the brake system (no air noticed after bleeding), my helper noticed that the brake pedel was up and hard at first but gradually would go to the floor while he was holding pressure on the pedel.

No air and no brake fluid leaks noticed anywhere. . what in the world is going on? Could it be the master cylinder is kapoot? Any help would be appreciatied.

 

[San Felipe Bob]

Sounds like a master cyl. to me.



SFB

 

[Loren]

Rusted brake lines

DMcQuown,



I can’t help with your current problem, but I want to report that your brake lines rusting through is not an isolated problem. My 1995 truck just did the same thing to me.



In my case, I got a “Brake” caution light about 20-50 miles before the brakes actually failed. I checked the fluid level (okay) and made a note to myself to look into it later.



While pulling the flatbed trailer, the truck brakes failed completely. Fortunately, the trailer had brakes. I limped home and then to the dealer. All of the brake lines were replaced and/or rebuilt.



Owners of older trucks beware! Check those brake lines if your truck is subject to chassis corrosion (road salt, parked outside, etc. ).



Loren

 

[WestTN]

a ring of crud will form on the master cylinder wall at the point where the rubber cup travels to normally when the brakes are applied. when you have a leak the rubber cup runs over this crud and destroys the sealing lip, allowing fluid to seep through . Then you have to clean and rebuild or replace the master cylinder.

 

[DMcQuown]

Thank everyone for the advice. I to believe it is the master cylinder but I didnt want to face the $$$$$$$$ to repair.



Again, thank everyone for the help

Dan