Help!!!! Ive changed my master cylinder, Brake booster, fluid and bleed the system countless of times and my brake is almost non existent. It'll stop but it takes a lot of effort. I check the vaccum and its pretty strong still. The pedal stays hard and it doesnt go down the floor or anything. I love this truck and I wont exchange this to my wifes Honda Pilot. Please advise anything to get this thing back on the road
Thanks All!!

 

What do your brake pads and rotors look like? Have you checked your calipers to make sure that all of the cylinders move freely? It does sound like a booster problem though.

 

Maybe your check valve is clogged or broken. It is the 90 degree piece that plugs into the booster and into the vacuum hose.

Willie

 

I would bite the bullet and take it to a brake shop.

 

Check valve works. I'll check the calipers but the pads are quite thick still. Its getting frustrating and I know a brake shop will try to screw me the moment he see's me pulling in. Does the D1 have a proportioning valve?

 

Was the hard pecal your original problem and the reason why you started replacing parts or was there different issue trying to be resolved and this was the result? With the master cylinder removed does your pedal move easily(pedal pivot possibly seized/rusted up)? Definitely check your calipers for seized pistons first though.

 

The original problem was my stopping distances was getting worse and thats when it all started. I did check my pedals when I took off the booster. I had to check because I accidentally broke the brake light switch. Will take my calipers apart today.

 

Have you tried just pulling the ABS fuse from under the hood?
I was having a similar intermintate ABS problem, pulled the fuse from the fuse box under the hood and no more problems, that was a year ago.

 

Hmmmmmm.... Will check it out.

 

This is assuming that you have a DI.
The ABS modulator goes bad and wont apply pressure to the brakes.
New ABS modulator...$1,000,000,000,000,000.
Pulling the ABS fuse and never having ABS problems again...priceless.