After a recent front brake caliper replacement, the brakes work great except that when moderate pressure is continually applied to the brake pedal, the pedal goes all the way to the floor. While driving down the road, when the brake pedal is depressed, the brakes engage right where you expect them to, and the van stops just fine, even if the stop is extreme. My question is, please explain what is going on? There is no air in the brake lines. The front calipers have been replaced twice, the back brake cylinders replaced, the master cylinder replaced, the RABS valve replaced, all by a certified shop trying to address this issue.
I spoke with the service manager at a local Ford dealer in Seattle and he was aware of the problem and said that there is no solution. He said the brakes will work fine. He couldn’t explain to me however, why this happens. If the van is not running, the brake pedal holds firm, so I assume the problem has something to do with either the ABS system or the power assist, but I can’t say for sure. I can live with this since the van stops great. However, I would sleep better if someone could explain to me what is mechanically going on that allows the brake pedal to go to the floor even though the brakes are fully engaged after the pedal is depressed say a third to a half way down to the floor (where you would expect).