Need some advanced advice...because I'm out of good answers.... so you smarty pants put on your thinking caps...

So here's the scenario. I have a 2005 Dodge Ram 2500 with the 5.9 Diesel. I just did a big brake replacement and changed all 4 calipers, pads and rotors. The braking system was working perfectly prior to the change...I just had one back rotor start sticking so I was replacing the whole shebang. Made the hardware swaps, did a manual pedal pump bleeding process...never got a firm pedal back. At no time did the master cylinder get low in the reservior to introduce air that way. Did that once or so more...still soft pedal down to like 75%. Did a vacuum bleed 3x, still no firm pedal. Limped it home slowly from my buddies shop...brakes will hold at stop and will slow down...its just that the pedal is down like 75-80% to the floor as it feels like it finally kicks in like "old non-assisted" brakes (if anybody remembers those).

My buddy brought over a service tool from the shop to see if there was an ABS brake bleed function (which apparently there is not) on this truck. He also brought over his power bleeder/flusher. We did a rotation of all four corner id say 4 more times. Still soft pedal. Interesting part is petal is reasonably firm when truck is off...but really softens up with the addition of the hydraulic brake booster. I did a trial drive to see if I could get the ABS module to kick in and activate the ABS braking...but could not. I got one wheel to pulse is all.

At this point, I've only come up with two answers for the problem....and I'm hoping someone can point me to a solid solution to fix it.

Possible problem #1) Somehow, air got into the ABS module - or particulates or junk from the old brake fluid and is keeping a valve open from the junk or air in the ABS module is making the pedal squishy until the bottom.

Possible problem #2) ....somehow, the pressure from the accumulator was released (i'm not SUPER familiar with how these work in the system) when I was manually pumping the brakes somehow that released something....

I believe I have the kelsey-hayes 4wal module...the module has the kelsey hayes name on the top, and my truck is 4wd with 4wheel ABS.

At this point, I'm not sure what the problem is. It has been bled at all 4 wheels and there is no air in those lines...which is why my focus is on the ABS module having air or junk or some other issue that's not on my radar at all.


THANKS so much for the input and advice...much appreciated and needed...it's my only truck and I need to get this figured out ASAP. I do have access to a professional scan / function tool through my buddy.

Cheers

 

go back and make SURE you installed all the calipers with the bleeder valves UP. the calipers can be installed on either side of the vehicle, and the bleeders will be at the top of the caliper ONLY if they are on the proper side of the vehicle. the bleeders HAVE to be at the top to get ALL the air out of the system. go check`em out and report back.

 

From the 2003 Dodge Service Manual...

STANDARD PROCEDURE - ABS BRAKE
BLEEDING
ABS system bleeding requires conventional bleeding
methods plus use of the DRB scan tool. The procedure
involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
HCU pump and solenoids. A second base brake bleeding
procedure is then required to remove any air
remaining in the system.
(1) Perform base brake bleeding,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(2) Connect scan tool to the Data Link Connector.
(3) Select ANTILOCK BRAKES, followed by MISCELLANEOUS,
then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time,(Refer
to 5 - BRAKES - STANDARD PROCEDURE) OR
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.

Best of luck!

 

I've bled the brakes myself on our 2004.5 with no issues but I've never replaced any brake components.

Numerous years ago we did the front brakes on a 2003 Dodge. Replaced the front calipers also. We could never get a firm or consistent pedal no matter what we did.
We even activated the ABS numerous times on a gravel road.

He took it to the Chrysler dealer who charged him too much to bleed the brakes while activating the ABS with the Chrysler diagnostic tool as Mike67RS detailed. Issue resolved.

 

Hey guys... just wanted to provide an update to you all. THANKS SO MUCH for the input. I did indeed bleed the brakes according to the manual and all that...the fronts were correct, but what was INCORRECT on our part is we/I did install the back calipers on the wrong side...that is to say the bleeder valves were on the bottom...I took them off this am, switched this am - did normal bleeding procedures and I have a firm pedal back. I couldn't get my ABS to activate on my gravel road...so I still may have to investigate that and have him bring back his diagnostic tool to test / activate the ABS system.

Thanks again...fundamentals first....

Cheers all! You can guarantee I'll check that EVERY time now on any brake job.....nipples up!!

Special thanks to jtamulonis!!!