Brake troubles contimplating suicide!

[Gitsum]

Ok here is one for you techs out there. 2002 24 valve 2500 Ram, 130,000 miles.
3 months ago I replaced a r/r brake caliper that locked up. 3 days ago I replaced the l/r caliper that locked up and today my l/f caliper locked up! I have a Bobcat skidsteer service and tow the Bobcat with my Ram. I have a Impulse brake control installed. I was towing today when the l/f locked up but was not towing when the other two locked up. Over the last 4-6 months I was noticing truck struggling intermittently as though I had an achor out. had it in shop but nothing found. Brake control was giving me trouble, Shows normal disconnected code E-1 when not hooked up. Would go to E-1 when hooked up on occasion. Would get out and wiggle 7-pin trailer connection and that would clear sometimes and sometimes not. When it did work I would get my brake setting showing on the brake control in the l.e.d..
Maybe coincidence but today when brake /caliper locked up I stopped at gas station (in cloud of smoke and burnt brake pad smell) and disconnected the main plug to brake control from under dash, had to get to job so decided to get in and drive it and burn it up or what ever it took to get the last 5 miles. When I got in after disconnecting the controller plug under dash the caliper was released and gave me no more problems to and back home from the job about a 25 mile drive. Brakes seem fine for now.
Was disconnecting the controller a pure coincidence or could it be the problem. If not how in the hell could I have 3 calipers go to crap in a 3 month period???????? plus 2 in 3 days!

Could I be having a conflict between the ABS and the Brake Controller? Is there a valve that may not be releasing the pads after letting off the brakes after a hard stop?

Help I need my truck for work and work is slow and every job counts right now. I own one truck and Bobcat so this is my bread and butter.
Thanks Alan

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2002 2500 Ram 24 valve Quadcab, 4x4K&N Filter, 33x12.50 BF Goodrich All Terrains, Polished aluminum 16.5 x 10 Rims, Bushwacker fender flares, 3" black tube steps, 138,000 miles,. 2nd ammendment supporter.

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Last edited by Gitsum : 08-20-2008 at 06:33 PM.

[Gitsum]

I see people lookin but they must not have a clue either! Can you tell me who i could pose the dilemma to?

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2002 2500 Ram 24 valve Quadcab, 4x4K&N Filter, 33x12.50 BF Goodrich All Terrains, Polished aluminum 16.5 x 10 Rims, Bushwacker fender flares, 3" black tube steps, 138,000 miles,. 2nd ammendment supporter.

[mishkaya]

Sorry I probably won't be of much help. Since you took it to a shop one would assume that the caliper pins are properly lubed and that the pads have not separated from the brackets. Those are two common problems on these trucks, especially the rear pads separating and causing the brakes to lock. I would also suggest a complete flush of the brake fluid if it hasn't been done recently as that could cause the pistons to stick. I am sorry I don't have any better suggestions than the basic stuff, but hopefully someone else will chime in here with some more pertinent advice.
Also I don't really see how the trailer brake controller could possibly be causing your brakes to stick. I am not sure which brake controller you have, but I can't possibly imagine how the problems could be linked.
Good luck.
mishkaya

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'01 6spd, Mach 6's, Helix 2 cam & springs, twins, Adrenaline, DD clutch, DOR bumper, etc...

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Last edited by mishkaya : 08-20-2008 at 07:04 PM.

[totalloser]

Man, I don't see how the two could be connected either. My first reaction would be to say scan the brain. It may throw some oddball brake code if the ABS is doing something funny. I would also make sure the abs motor is not running when this happens. Maybe if it happens pull the harness from the abs brain to the abs pump motor to see if it stops. It's on the left side of the firewall right by the master cylinder. Mine is locked on (stuck relay in brain) so I have been running unplugged forever. Same boat as you almost. Have to tow my junk (Takeuchi exc/JD ldr/hoe) with a Tacoma when the Dodge needs work. I like mishkaya's suggestion to flush the brakes. Can't hurt, and air in the lines can do some funky things.

Another thing to watch for is PS fluid in the system, but usually when the booster lets go it is not ONE that locks up, but ALL of them. And usually it doesn't handily unlock. I know this isn't probably too helpful. Maybe someone else will chime in.

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01 24v 100hp tips, 4"ss BDbrake &steering brace PSCpump 1.5"dom steering tapped box 1.5"ram manual CAD switch dual carters 3.55's LSD, big shaft nv5600/241HD 6 35's inners pulled in (no spacer) Ugly black and thrashed!

[Gitsum]

Hey keep the ideas comin, I am gonna bleed both of the front brake calipers real good tomorrow since I have recently bled the back two when I replaced em. I was already thinking about diconnecting the abs also could someone give me real explicit info on pullin' the plug on the abs. I am very mechanically inclined like most of us 52 year old heavy equip operators but don't know squat about the abs crap.!

Originally Posted by totalloser

Man, I don't see how the two could be connected either. My first reaction would be to say scan the brain. It may throw some oddball brake code if the ABS is doing something funny. I would also make sure the abs motor is not running when this happens. Maybe if it happens pull the harness from the abs brain to the abs pump motor to see if it stops. It's on the left side of the firewall right by the master cylinder. Mine is locked on (stuck relay in brain) so I have been running unplugged forever. Same boat as you almost. Have to tow my junk (Takeuchi exc/JD ldr/hoe) with a Tacoma when the Dodge needs work. I like mishkaya's suggestion to flush the brakes. Can't hurt, and air in the lines can do some funky things.

Another thing to watch for is PS fluid in the system, but usually when the booster lets go it is not ONE that locks up, but ALL of them. And usually it doesn't handily unlock. I know this isn't probably too helpful. Maybe someone else will chime in.

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2002 2500 Ram 24 valve Quadcab, 4x4K&N Filter, 33x12.50 BF Goodrich All Terrains, Polished aluminum 16.5 x 10 Rims, Bushwacker fender flares, 3" black tube steps, 138,000 miles,. 2nd ammendment supporter.

[Meierznutz]

Where does the brake controler hook up? Is it to the factory plug under the dash with the pigtail that came with the truck? If not, and then again check anyway, look for frayed wires near that connector that could be throwing off the ABS controler. Also, if you tow heavy and drive hard, it's not unthinkable that the calipers are taking some heat. Especially if the controler has been working on and off due to a loose plug at the hitch. Those few stops where the truck did ALL the work could cook a caliper to death in a hurry. I would flush the fluid from the whole system and maybe go up to DOT-4 fluid as it has a higher boiling point (check to see if the system can handle it first). I would doubt PS fluid in the brake system unless it was topped off that way. The PS and brakes are completely seperate and only share a drive pin (still sealed from one another by 2 seals at that point, both would have to leak and the PS would have to be at a high enough presure to push past both seals and not leak out of the housing. check bled fluid for contamination to be sure). Good Luck... Chris

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'02 2500 QC SB 6 Sp, Con-OFE, Banks Brake and Monster Exhaust, JL Stealth Sub, AM Lunar gauges, Air Dog Raptor, Home built Hybrid 35/40 pushing 33psi!
Is there a Mega Cab in my future??? P.S. This truck for sale.

[Gitsum]

I as I said just replaced the two back calipers so I know they are good and lubed so today I removed both front calipers and discs. I cleaned the pads, calipers, clips and the two caliper bolts. I then coated all of the moving parts and contact areas of the clips, bolts and bolt tubes with a thin film of "Never Seize". I also flushed the old brake fluid and added new Synthetic Dot 3-Dot-4 equivalent. As far as the controller goes I am taking the truck to my local trailer shop and having them check all of the wiring on the truck and my Bobcat trailer and having them install a High quality brake contoller. I bought the last one (Impulse) at Tractor Supply for $50.......................gues ya get what ya pay for. And yes I had purchased the proper pigtail for the controller and plugged it into the recepticle for the controller that's supplied up under the dash left of the steering wheel above the emergency brake.
Drove it 15 miles today after repairs and did some hard stops and long slow stops and everything seems fine. The caliper slide bolts were sticky and gooey with dried lube on them and the rest of the caliper and disck ends were rusted pretty bad (Florida coast environement).
The stainless disc retaining clips were also all gunked up.
Maybe the disc just jammed. We'll see what happens.
Thanks for all the advise guys, if they lock up again I'll be back cryin'!

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2002 2500 Ram 24 valve Quadcab, 4x4K&N Filter, 33x12.50 BF Goodrich All Terrains, Polished aluminum 16.5 x 10 Rims, Bushwacker fender flares, 3" black tube steps, 138,000 miles,. 2nd ammendment supporter.

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Last edited by Gitsum : 08-21-2008 at 06:16 PM. Reason: mispelled words

[kdhrick]

Do you do any off roading with water or maby salt from winter driving?
Just a thought. I like others don't see any connection between the controler and the truck brakes
Good Luck

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2006 2500 Inferno Red Quad Cab, Bully Dog Tri W/monitor, Amsoil bypass, Amsoil fluids throughout, Line X bed liner, rear wheel well liners, Luverne step sides

[Gitsum]

I live on the gulf coast of north Florida. I hunt and fish and it's 4 wheel drive. Nuf said.

__________________
2002 2500 Ram 24 valve Quadcab, 4x4K&N Filter, 33x12.50 BF Goodrich All Terrains, Polished aluminum 16.5 x 10 Rims, Bushwacker fender flares, 3" black tube steps, 138,000 miles,. 2nd ammendment supporter.

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Last edited by Gitsum : 08-21-2008 at 08:32 PM.