Brake carnage!!

[CGMKCM]

I would flush and refill power steering/hydro boost system with schaeffer's all trans supreme. power steering/hydroboost flush

 

[Ktrim]

Who's going to work in Mexico anyway. They're all here.

 

[Fordtech86]

Who's going to work in Mexico anyway. They're all here.

next room down

on your right

 

[Ktrim]

next room down

on your right

Yeah wrong thread long day at work

 

[Fordtech86]

Yeah wrong thread long day at work

it happens my friend!

 

[mcmxi]

I would flush and refill power steering/hydro boost system with schaeffer's all trans supreme. power steering/hydroboost flush

Thanks for the suggestion. I use and like Schaeffer products and ordered the one gallon container of All Trans Supreme last night.

All-Trans Supreme® | Schaeffer Oil

Schaeffer's ALL-Trans Supreme is a superior alternative transmission fluid to Dexron III, Mercon, Mercon V, and Allison C-4 type fluids.

www.schaefferoil.com

The Motive brake bleeder kit is supposed to show up today so I can finally get the brakes bled this afternoon and the truck back on the road.

 

[mcmxi]

Well, another big thank you to @The Evil Twin for suggesting a Motive brake bleeder. I've worked on brakes many, many times over the last forty years and have bled many brake systems, but almost always with a helper that has the horrible job of pumping the brakes.

This Motive kit is worth every penny of the $100 or so that it cost. I added a quick disconnect but after thinking about it, the reservoir adapter cap only has to turn 120 degrees to engage the tabs so I don't think it's necessary.

I pressurized the system before adding any brake fluid to the tank to make sure there were no leaks and all was good. I ended up bleeding all four calipers twice due to the color of the brake fluid. It's was a black/green at first and after flushing close to two quarts through I ended up with a lime green solution and a very clean and clear reservoir. I wonder if the green is from degrading brake hoses. Since I'll need to bleed the brakes again when I install the braided stainless steel hoses I'll call it good for now.

Next up will be flushing the power steering system as suggested by @CGMKCM.

Brake fluid from the first go around.

Brake fluid after the second go around.

The reservoir and the fluid in it is the cleanest it's ever been in the time I've owned the truck.

 

[CGMKCM]

I found another video that goes over flushing power steering and power boost system. This might provide a better process for getting the job done. 7.3l Steering flush.

 

[mcmxi]

I found another video that goes over flushing power steering and power boost system. This might provide a better process for getting the job done. 7.3l Steering flush.

I had watched that video on Tuesday night in preparation for flushing the power steering system and I basically did what was suggested. I was under some pressure to get the tractor and disc loaded up on Wednesday so rushed through the process. I don't think the ATF in the system was that bad and I probably should have kept on flushing but I'll get back to it soon and run the rest of the gallon through. It would have been good to have help so that I could watch the ATF level in the reservoir and to see the color of the ATF being pumped out.

The brake pedal feels a lot better now but I'm looking forward to new stainless steel braided hoses and another brake flush.

 

[lugbolt]

flushing the brake fluid once in a while is a VERY good idea. Keeps the calipers and hoses from falling apart, among other things. Most folks don't change fluid until it's time to replace parts...and even then it doesn't get flushed. ABS systems MUST be flushed periodically, if not the ABS motor assembly will fail sooner than it would if the fluid is flushed.

same for power steering and in this case, hydroboost. Flushing once in a while isn't terribly hard to do and saves parts failures. Systems work better too.

and coolant. Nobody ever changes coolant because "it's got a lifetime interval". Define lifetime. 50,000 miles or 40,000?

I do it once a year on all counts. My truck sits a lot and sitting isn't good for them, in some ways worse than actually using it. It may be sitting a lot more this year....I am no longer guiding, and having to really watch the pennies closer, as there are a lot fewer of them coming in now. May end up selling it.

 

[mcmxi]

flushing the brake fluid once in a while is a VERY good idea. Keeps the calipers and hoses from falling apart, among other things. Most folks don't change fluid until it's time to replace parts...and even then it doesn't get flushed. ABS systems MUST be flushed periodically, if not the ABS motor assembly will fail sooner than it would if the fluid is flushed.

same for power steering and in this case, hydroboost. Flushing once in a while isn't terribly hard to do and saves parts failures. Systems work better too.

and coolant. Nobody ever changes coolant because "it's got a lifetime interval". Define lifetime. 50,000 miles or 40,000?

I do it once a year on all counts. My truck sits a lot and sitting isn't good for them, in some ways worse than actually using it. It may be sitting a lot more this year....I am no longer guiding, and having to really watch the pennies closer, as there are a lot fewer of them coming in now. May end up selling it.

I towed the boat yesterday afternoon and the brakes are so much better now. They'll be even better once I have the new brake hoses installed, and have performed another flush of the power steering fluid.

 

[mcmxi]

A bit of an update on the brakes. They're the best they've ever been since I've owned this truck, and the KLM stainless steel braided brake lines shipped today. I ordered them on 6/9 and the website states "28 days minimum to manufacture" which is basically the time it took if you count working days.

The lines are shipping via USPS so will probably take a week to get here. I'll post a final update once the they're installed and I've used that fancy Motive brake bleeder again to purge all the air. I'm curious to see if the color of the brake fluid returns to clear once the 22 year old hoses are in the trash can.

 

[CGMKCM]

A bit of an update on the brakes. They're the best they've ever been since I've owned this truck, and the KLM stainless steel braided brake lines shipped today. I ordered them on 6/9 and the website states "28 days minimum to manufacture" which is basically the time it took if you count working days.

The lines are shipping via USPS so will probably take a week to get here. I'll post a final update once the they're installed and I've used that fancy Motive brake bleeder again to purge all the air. I'm curious to see if the color of the brake fluid returns to clear once the 22 year old hoses are in the trash can.

FWIW, I added this filter in my return line after flushing the power steering. It is easy to remove and clean. NAPA

 

[mcmxi]

The KLM brake lines showed up today and I'm impressed with the quality. I've had stainless braided lines on my Jeep TJ for at least 10 years, but they don't have a clear protective sheath around them like the KLM version. I'll most likely get them installed in a couple of weeks once I'm back from a work trip.

 

[DustyRusty]

FWIW, I added this filter in my return line after flushing the power steering. It is easy to remove and clean. NAPA

I checked my local NAPA and it isn't stocked by them. This is what the online search came back with .......
105 stores within 60 miles of 06260-1347 not one store had the filter in stock, but most could order it and get it in a few days.

 

[mcmxi]

I installed the new KLM brake hoses a couple of weeks ago and flushed the brake system a few times using the Motive kit. Replacing the brake rotors and pads in combination with flushing the brake fluid provided the most significant improvements. I can't say that the new lines made a whole lot of difference to pedal feel. Perhaps during hard use there will be less brake fade with the new lines.

On another note, I almost didn't make it home from town a couple of days ago. I was waiting at a stop light, went to pull away and the truck had no power, was running really rough and there was lots of black smoke coming out of the exhaust. I'm talking LOTS of black smoke .... an embarrassing amount. I managed to limp home but almost didn't make it up the driveway.

I have a chip and programmer with a built in code scanner which showed Fuel Injector Control Module (FICM) issues. Once I got home, I plugged in a code scanner and it confirmed a problem with the FICM. I ordered a rebuilt and upgraded FICM for $255 which will be here early next week. While I'm waiting for the part I'm going to pull the valve covers and replace all eight glow plugs.

This '02 has been amazing in the time I've owned it with no major issues. The FICM is a known problem area since it lives in the engine compartment where it can get wet, but given that the OEM unit has been in there for 22 years and 180,000 miles it's done well. The new one is a sealed unit.

 

[The Evil Twin]

I installed the new KLM brake hoses a couple of weeks ago and flushed the brake system a few times using the Motive kit. Replacing the brake rotors and pads in combination with flushing the brake fluid provided the most significant improvements. I can't say that the new lines made a whole lot of difference to pedal feel. Perhaps during hard use there will be less brake fade with the new lines.

On another note, I almost didn't make it home from town a couple of days ago. I was waiting at a stop light, went to pull away and the truck had no power, was running really rough and there was lots of black smoke coming out of the exhaust. I'm talking LOTS of black smoke .... an embarrassing amount. I managed to limp home but almost didn't make it up the driveway.

I have a chip and programmer with a built in code scanner which showed Fuel Injector Control Module (FICM) issues. Once I got home, I plugged in a code scanner and it confirmed a problem with the FICM. I ordered a rebuilt and upgraded FICM for $255 which will be here early next week. While I'm waiting for the part I'm going to pull the valve covers and replace all eight glow plugs.

This '02 has been amazing in the time I've owned it with no major issues. The FICM is a known problem area since it lives in the engine compartment where it can get wet, but given that the OEM unit has been in there for 22 years and 180,000 miles it's done well. The new one is a sealed unit.

View attachment 138984

How was the installation? Everything line up well with a proper amount of slack?
I'm going to order a set myself this winter. The flushing and a new set of tires will be due. I figure to do it all and only take the wheels off once.

 

[mcmxi]

How was the installation? Everything line up well with a proper amount of slack?
I'm going to order a set myself this winter. The flushing and a new set of tires will be due. I figure to do it all and only take the wheels off once.

Overall I'd say that the installation wasn't too bad, but I could have opted for the factory length hoses up front rather than the +2" or whatever I went with. I had to adjust the retention clips for the front hoses which use the factory bracket, and there's no way to reuse the plastic clips that hold the brake hose, 4WD vacuum hose and ABS lines together. I used zip ties which I'm not thrilled about but what else could I do? The rear hoses use a new bracket which oddly has two holes in it even though there's only one tapped hole on the spring perch.

In the bottom picture you can see the hose that connects the rear axle hard lines to the hard line that runs along the frame to the master cylinder.

 

[The Evil Twin]

Overall I'd say that the installation wasn't too bad, but I could have opted for the factory length hoses up front rather than the +2" or whatever I went with. I had to adjust the retention clips for the front hoses which use the factory bracket, and there's no way to reuse the plastic clips that hold the brake hose, 4WD vacuum hose and ABS lines together. I used zip ties which I'm not thrilled about but what else could I do? The rear hoses use a new bracket which oddly has two holes in it even though there's only one tapped hole on the spring perch.

In the bottom picture you can see the hose that connects the rear axle hard lines to the hard line that runs along the frame to the master cylinder.

View attachment 138992

View attachment 138993

View attachment 138994

Good input. Thank you.
I already relocated my front brake hard lines when I added 1.5" up front. So I'll probably just go stock length.
Are these the clips you are referring to? I could just walk out to the shop and look at my truck. But it's raining. Lol.

https://www.amazon.com/ABS-Sensor-Line-Clips-Pack/dp/B09QDVHQCT

 

[mcmxi]

Good input. Thank you.
I already relocated my front brake hard lines when I added 1.5" up front. So I'll probably just go stock length.
Are these the clips you are referring to? I could just walk out to the shop and look at my truck. But it's raining. Lol.

https://www.amazon.com/ABS-Sensor-Line-Clips-Pack/dp/B09QDVHQCT

That's not the clip. There are two plastic clips on each set of hoses up front so four in total. I'll see if I can find one in the garage, or possibly look through some phots to see if the clip is visible.