Ford Brakes/Suspension :: 2003 F350 - All 4 Brakes Dragging


May 8, 2016

Here's the deal:

* Drive the truck after it's been sitting a while (overnight, or at least a couple of hours), everything's fine. Good brake pedal feel.

* Drive 10-15 miles, stop-and-go at lights and stop signs, the brake pedal slowly goes from normal to firm, to very firm. Then, no play whatsoever and brakes are dragging bad. Yesterday, they were dragging so bad that I had it pulled into 1st gear with pedal on the floor just to get thru an intersection.

* Get out and check each wheel, all 4 brakes are dragging. I can tell from the heat pouring out of each wheel. And I've verified with infrared thermometer. Also, I've raised the vehicle when this is happening, and all 4 wheels will not turn. So it's definitely all 4 brakes.

At first, I assumed it was seized slide pins. But I've THOROUGHLY cleaned each and every one, and lubed with synthetic caliper grease. When the brakes are feeling normal, I've had my wife pump the brakes while I watched the calipers. Near as I can tell, they slide easily. Again, when my problem happens, it's all 4 wheels SIMULTANEOUSLY. So I've pretty much ruled out slide pins.

The brake pedal itself isn't getting bound by anything. It moves freely and I've lubed each of the pivot points. No problems there.

* When the brakes are dragging, I can crack the bleed screws and some fluid will come out at each wheel, which releases the brake at that wheel and I can then turn each wheel freely. So, there's residual pressure in the lines. I replaced the master cylinder (twice actually). No change in behavior.

BTW: I thoroughly bled the lines after each of the two master cylinder changes. I must've put 60+ ounces of fresh/clean/new fluid into the system so this isn't related to old fluid.

* Next, when the brakes are dragging, I can unscrew the master cylinder about 1/8-inch or so from the booster, and the brakes immediately release. Again, indicating residual pressure in the lines. So, I assume that something funky is going on with the brake booster. Also, when the brakes are dragging, I can pull the vacuum hose from the brake booster. And after a few seconds the brakes release. So I installed a new brake booster (re-manufactured one from NAPA -- they didn't offer a brand new one). No change in behavior.

After swapping the brake booster, I can still pull the vacuum tube when the brakes are dragging and it'll release in just a few seconds. So, it really seems like something is going on with the booster, but I can't figure out what it might be.

It is possible for the brake booster vacuum tube to have TOO MUCH vacuum, thereby causing the brakes to be unknowingly applied? Is there maybe a regulating valve of some kind in the line?

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