How to fix brakes that will not release?

anual Bleeding
The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. Bleed the longest line first on the individual system being serviced. During the complete bleeding operation, DO NOT allow the brake master cylinder reservoir (2K478) to run dry. Keep the master cylinder reservoirs filled with High Performance DOT-3 Brake Fluid C6AZ-19542-AA or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time.
NOTE: Non-ABS vehicles have the brake master cylinder (2140) mounted at an angle to the horizontal, bleeding may be better performed if the vehicle is positioned so that the brake master cylinder is horizontal.

1. To bleed the brake system, position a suitable box wrench on the bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting. The end of the tube should fit snugly around the bleeder fitting.

1. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting approximately three-quarters of a turn.

1. Have an assistant push the brake pedal (2455) down slowly through its full travel. Close the bleeder fitting, then return the brake pedal to full-release position. Repeat this operation until air bubbles cease to appear at the submerged end of the bleeder tube.

1. When the fluid is completely free of air bubbles, secure the bleeder fitting and remove the bleeder tube.

1. Repeat this procedure at the brake wheel cylinder on the opposite side. Refill the brake master cylinder reservoir after each wheel cylinder is bled, and install the master cylinder cap and gasket. Ensure the diaphragm-type gasket is properly positioned in the master cylinder cap. When the bleeding operation is completed, the fluid level should be at the MAX line to 4.0 mm (0.16 inch) below.

1. If the primary (front brake) system is to be bled, repeat Steps 2 through 5 at the right front brake caliper and ending at the left front brake caliper. Bleed the brake master cylinder at the bleed screw after all calipers are bled.

1. After disc brake service, ensure that the disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. This is accomplished by depressing the brake pedal several times until normal pedal travel is established.

1. Check pedal feel. If brake pedal feels "spongy" repeat bleed procedure, or use the Vacuum method as outlined in Section 06-09, but bleed both rear calipers first.

You can also pressure bleed it. If the abs module needs to be bleed, that requires a special tool. If you have already tried the procedure posted and it didn't work, I'm not sure what next?

If you are loosing prime in the system but not loosing fluid my best guess would be the master cylinder.

I just had a simalar problem on a suzuki sidekick.. It turned out to be a bad piston seal inside the Master Cyl. I went through about a gallon of fluid before i took the master cyl apart.. because it was a "rebuilt" cylinder from a trusted brand name company.. So i called the rebuilding compang and they sent me one that they had checked.. It worked great and fixed the problem.. by the way did i mention that i had received 3 units from the parts store all with the same problem.. finally i took one apart and discovered the problem.

Hi Kathy, I'm guessing that you mean you've replaced the brake master cylinder. It helps to be as specific as possible, so we can help you in a specific way. Make sure that the brake fluid pipes connecting the master cylinder are sealing correctly. There must be no leakage from them at all. Fill the reservoir and keep it filled throughout the whole bleeding procedure by having someone topping up each time the level goes down. Begin the bleeding procedure at the wheel furthest from the master cylinder and move one wheel at a time closer. The procedure is to push the pedal repeatedly to the floor and releasing to come full travel to the top of its movement. Repeat several times and while holding the pedal fully depressed to the floor open and close the bleeding valve on the wheel being bled before beginning the pumping action over. Once all wheels have been bled and you have reached the wheel closest to the master cylinder, if the pressure in the system is insufficient repeat the whole job until brake pedal pressure is normal. Look for signs of leakage on all four wheels in the event there is a leak on a wheel cylinder. The brake warning light should extinguish when the park brake is released and the ABS light when pressure is normal in the system, unless there is another separate fault. Finish up on the bleeding first and let me know how you get on. We'll tackle one job at a time. Regards John

1. Check the fluid level in the reservoir after bleeding each wheel. Add DOT3 fluid, if necessary.
2. If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air from the master cylinder as follows:
   1. Disconnect the brake lines from the master cylinder.
   2. Slowly depress the brake pedal and hold it.
   3. Block off the outlet plug with your finger, and release the brake pedal.
   4. Repeat 3 or 4 times.
   
   
3. Bleed the brake starting with the one furthest from the reservoir and then the next furthest, etc.
   
4. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down.
5. At the point when fluid stops coming out, tighten the bleeder plug to 11 Nm (8 ft. lbs.), then release the brake pedal.
6. Repeat until all the air in the fluid has been bled out.
7. Repeat the procedure to bleed the air out of brake line for each wheel.
8. Check the fluid level and add DOT3 fluid if necessary.

MANUAL BLEEDING

For those of us who are not fortunate enough to have access to a power bleeding tool, the manual brake bleeding procedure will quite adequately remove air from the hydraulic system. The major difference between the pressure and manual bleeding procedures is that the manual method takes more time and will require help from an assistant. One person must depress the brake pedal, while another opens and closes the bleeder screws.

In addition to a length of clear neoprene bleeder hose, bleeder wrenches and a clear bleeder bottle (old plastic jar or drink bottle will suffice), bleeding late-model ABS systems may also require the use of one or more relatively inexpensive combination valve pressure bleeding tools (which are used to depress one or more valves in order to allow component/system bleeding). To fully bleed the late model ABS systems, a scan tool should also be used to run the system through functional tests.

1. Clean the top of the master cylinder, remove the cover and fill the reservoirs with clean fluid. To prevent squirting fluid, and possibly damaging painted surfaces, install the cover during the procedure, but be sure to frequently check and top off the reservoirs with fresh fluid.

CAUTION Never reuse brake fluid which has been bled from the system.

1. The master cylinder must be bled first if it is suspected to contain air. If the master cylinder was removed and bench bled before installation it must still be bled, but it should take less time and effort. Bleed the master cylinder as follows:
   1. Position a container under the master cylinder to catch the brake fluid.

WARNING Do not allow brake fluid to spill on or come in contact with the vehicle's finish as it will remove the paint. In case of a spill, immediately flush the area with water.

1. Loosen the front brake line at the master cylinder and allow the fluid to flow from the front port.
   
2. Have a friend depress the brake pedal slowly and hold (air and/or fluid should be expelled from the loose fitting). Tighten the line, then release the brake pedal and wait 15 seconds. Loosen the fitting and repeat until all air is removed from the master cylinder bore.
   
3. When finished, tighten the line fitting to 20 ft. lbs. (5 Nm).
   
4. Repeat the sequence at the master cylinder rear pipe fitting.

During the bleeding procedure, make sure your assistant does NOT release the brake pedal while a fitting is loosened or while a bleeder screw is opening. Air will be drawn back into the system.

1. Check and refill the master cylinder reservoir.
   

Remember, if the reservoir is allowed to empty of fluid during the procedure, air will be drawn into the system and the bleeding procedure must be restarted at the master cylinder assembly.

1. On late model ABS equipped vehicles, perform the special ABS procedures as described later in this section. On 4 wheel ABS systems the Brake Pressure Modulator Valve (BPMV) must be bled (if it has been replaced or if it is suspected to contain air) and on most Rear Wheel Anti-Lock (RWAL) systems the combination valve must be held open. In both cases, special combination valve depressor tools should be used during bleeding and a scan tool must be used for ABS function tests.

1. If a single line or fitting was the only hydraulic line disconnected, then only the caliper(s) or wheel cylinder(s) affected by that line must be bled. If the master cylinder required bleeding, then all calipers and wheel cylinders must be bled in the proper sequence:
   1. Right rear
      
   2. Left rear
      
   3. Right front
      
   4. Left front
2. Bleed the individual calipers or wheel cylinders as follows:
   1. Place a suitable wrench over the bleeder screw and attach a clear plastic hose over the screw end. Be sure the hose is seated snugly on the screw or you may be squirted with brake fluid.

Be very careful when bleeding wheel cylinders and brake calipers. The bleeder screws often rust in position and may easily break off if forced. Installing a new bleeder screw will often require removal of the component and may include overhaul or replacement of the wheel cylinder/caliper. To help prevent the possibility of breaking a bleeder screw, spray it with some penetrating oil before attempting to loosen it.

1. Submerge the other end of the tube in a transparent container of clean brake fluid.
   
2. Loosen the bleed screw, then have a friend apply the brake pedal slowly and hold. Tighten the bleed screw to 62 inch lbs. (7 Nm), release the brake pedal and wait 15 seconds. Repeat the sequence (including the 15 second pause) until all air is expelled from the caliper or cylinder.
   
3. Tighten the bleeder screw to 62 inch lbs. (7 Nm) when finished.

1. Check the pedal for a hard feeling with the engine not running. If the pedal is soft, repeat the bleeding procedure until a firm pedal is obtained.
   
2. If the brake warning light is on, depress the brake pedal firmly. If there is no air in the system, the light will go out.
   
3. After bleeding, make sure that a firm pedal is achieved before attempting to move the vehicle.

Hope helps (remember to rate this answer).

Hi, your proportioning valve is stuck. Take the caps off and recenter the one stuck valve. Then rebleed the system using the procedure below. Thanks for using fixya.


For those of us who are not fortunate enough to have access to a power bleeding tool, the manual brake bleeding procedure will quite adequately remove air from the hydraulic system. The major difference between the pressure and manual bleeding procedures is that the manual method takes more time and will require help from an assistant. One person must depress the brake pedal, while another opens and closes the bleeder screws.

1. Deplete the vacuum reserve by applying the brakes several times with the ignition OFF .
2. Clean the top of the master cylinder, remove the cover and fill the reservoirs with clean fluid.
3. The master cylinder must be bled first if it is suspected to contain air. If the master cylinder was removed and bench bled before installation it must still be bled, but it should take less time and effort. Bleed the master cylinder as follows:
   1. Position a container under the master cylinder to catch the brake fluid.
   2. Loosen the front brake line(s) at the master cylinder and allow the fluid to flow from the front port.
   
   

WARNING Do not allow brake fluid to spill on or come in contact with the vehicle's finish as it will remove the paint. In case of a spill, immediately flush the area with water.

1. Tighten the line connection(s).
2. Have an assistant depress and hold the brake pedal.
3. Loosen the line connection(s) again, allowing air to escape from the master cylinder.
4. Tighten the line(s), then have the assistant release the brake pedal and wait for 15 seconds.
5. Repeat steps D through F until the line(s) are free of air.
6. When finished bleeding the air from the master cylinder, tighten the line connections to 20 ft. lbs. (27 Nm).
7. Repeat steps B through H, only with the master cylinder rear pipe fitting(s).

1. Refill the master cylinder with fresh brake fluid.

WARNING Never reuse brake fluid that has been bled from the system.

1. If a single line or fitting was the only hydraulic line disconnected, then only the caliper(s) or wheel cylinder(s) affected by that line must be bled. If the master cylinder required bleeding, then all calipers and wheel cylinders must be bled in the proper sequence:
   1. Right rear
   2. Left rear
   3. Right front
   4. Left front
   
   
2. Bleed the individual calipers or wheel cylinders as follows:
   1. Place a suitable wrench over the bleeder screw and attach a clear plastic hose over the screw end. Be sure the hose is seated snugly on the screw or you may be squirted with brake fluid.
   2. Submerge the other end of the tube in a transparent container of clean brake fluid.
   3. With the help of an assistant, apply the brake pedal slowly and hold.
   
   

During the bleeding procedure, make sure your assistant does NOT release the brake pedal while a fitting is loosened or while a bleeder screw is opening. Air will be drawn back into the system.

1. While the assistant continues to apply pressure to the brake pedal, loosen the bleeder screw, and watch for air bubbles in the container.

Be very careful when loosening the wheel cylinder and brake caliper bleeding screws. The bleeder screws often rust in position and may easily break off if forced. To help prevent the possibility of breaking a bleeder screw, spray it with some penetrating oil before attempting to loosen it. Installing a new bleeder screw will often require removal of the component and may include overhaul or replacement of the wheel cylinder/caliper.

1. Tighten the bleeder screw.
2. Instruct the assistant to release the brake pedal.
3. Wait approximately 15 seconds, and instruct the assistant to depress the brake pedal again.

Remember, if the reservoir is allowed to empty of fluid during the procedure, air will be drawn into the system and the bleeding procedure must be restarted at the master cylinder assembly.

1. Repeat steps C through F until there are no air bubbles present in the container.

1. Check the pedal for a hard feeling with the engine not running. If the pedal is soft, repeat the bleeding procedure until a firm pedal is obtained.
2. If the brake warning light is on, depress the brake pedal firmly. If there is no air in the system, the light will go out.
3. Once all the air is bled from the system, install the bleeder screw caps.
4. After bleeding, make sure that a firm pedal is achieved before attempting to move the vehicle.

Here is the procedure from the service manual. I would add just one thing. Do each wheel in this order

1. right rear wheel
2. left rear wheel
3. right front wheel
4. left front wheel

BLEEDING

HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system.

NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.


a)FILL BRAKE RESERVOIR WITH BRAKE FLUID Fluid:SAE J1703 or FMVSS No. 116 DOT3

b)BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.

c)Disconnect the brake lines from the master cylinder. SST 09023-00100 Slowly depress the brake pedal and hold it.

Block off the outlet plug with your finger and release the brake pedal.
Repeat (b) and (c) 3 or 4 times.


BLEED BRAKE LINE

1. Connect the vinyl tube to the caliper or wheel cylinder bleeder plug.
2. Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down.
3. At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Torque: (Bleeder plug) Front brake caliper
: 8.3 Nm (85 kgf-cm, 74 inch lbs.) Rear wheel cylinder: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
4. Repeat (b) and (c) until all the air in the fluid has been bled out.
5. Repeat the above procedure to bleed the air out of the brake line for each wheel.

CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3

When you fixed the brakes, did you take the lid off the master cylinder. I just wonder if you spilled out your brake fluid. The only reason the pedal should go to the floor is if the brake fluid is gone or the master cylinder is not working. Check the fuse. Check the brake fluid level. The pedal only goes to the floor if there is no back pressure in the lines between the master cylinder the lines to the brake pistion on the calipers. Please give me a good ratin and keep me informed.

Honestly your guess is as good as mine. But I don't think the master cylinder is NOT bad you still have air in the system. Get a big bottle of brake fluid bleed all four sides until you run out of fluid or your brakes work properly. You should divide the bottle's content in four, then use each quantity in each side. You'll be removing air and contaminated fluid from the system. Get a small hose that fits on the bleeders and an appropriate container. I have a good feeling if you do this your brakes will work just fine. I don't know how you are bleeding the brakes. I'll let you know the proper way just in case. This is a two man job, with the wheel off, have someone start the car. Have them pump the brakes a few times to get pressure. 1With the brake pedal UP open the bleeder, 2then have your assistant press the brake pedal all the way down and leave it completely pressed down. 3Close the bleeder valve, once close and only with the valve closed have'm release the brake. Repeat as necessary, bake depressed, open valve first then press brake. DO NOT depress until valve completly closed. Close valve THEN depress. Good Luck!