No brake pedal

[Nenaf]

2011 ford fusion 2.5L SEL automatic the brake pedal was engaging very low. I knew something was wrong. I figured its the master cylinder so i bought a new doorman not rebuilt. I stalled and tried to bleed brakes but didnt get hardly any fluid from the rear drivers side or front passenger caliper. Pedal would go to the floor. I bench bleed the master before installing based on procesure to attach two plastic screws to plug both ports before priming /bleeding the master. I could see air escape. Did this several times and tapped it lightly with screw driver handle to help free up any other air pockets. I could still push the plunger down about an inch. Installed the new master and bleed system but pedal goes to the floor. Bought a second master, same procedure and pedal goes to the floor. I hooked forscan and initiated abs brake bleed. No fluid came out of the driver rear caliper during the procedure. Not sure if your suppose to bleed the lines while forscan is running. Brake Pedal still goes to floor. I then connected a vacum hand bleed pump to each caliper and bleed again all the way around. Brake pedal still goes to the floor. Initiated forscan again but no difference. 

Is it two bad master cylinders i got or is there something im missing.when bleeding the system. I bleed rears then fronts but it seems still no brake pressure. 

Any suggestions are welcome. Ive never seen a car behave like this.  I figure i should get some pedal etc but so far no luck.

Thanks everyone. 

Nenad

 

[Nenaf]

Update. Kept pressing brake pedal quickly/erratically and then bleed the brakes again using forscan and bleed procedure. Looks like abs pump had air trapped in it. Got the air out finally after  bleeding each caliper 3 times between running forscan bleed procedure 3 times per caliper. Pedal was still a liytle spongee so didnthe same procedure again all the way around and pedal is now very hard while vehicle is off or on.  Will keep an eye to see if maybe abs module acts up after some time. When using forscan and starting to get pedal i could hear the pump sound actually going from a higher pitch tone to a lower pitch tone which means its bleeding and there was lots of back pressure on the brake pedal when the bleed feature was activated. The pedal would go down and then get pushed back up while doing the bleed abs step.

[popeyz]

what is forscan?

[bbf2530]

10 hours ago, popeyz said:

what is forscan?

 

Hi popeyz. FORScan is a software that can be used in connection with a laptop and OBDII USB connecter to access the OBDII and other systems in our modern Ford/Lincoln vehicles. It can also be used to access and reprogram certain vehicle parameters and settings.

 

See here: https://forscan.org/home.html

 

Good luck.

[popeyz]

i kinda thought it was something like that..   Thank you for your fast response.

 

[Farmer Dunn]

Ford has a recall for the excessive brake pedal travel, however they don't know how to fix their own problem. My 2009 had that issue, the brakes went almost all the way to the floor when stopping. I bled the brakes multiple times, computer bled the abs module, replaced rotors and pads, because they were below spec, and still the same issue. While researching for answers I came across the recall. I called Gateway Ford which offered to fix it for free under the recall. Over a month goes by with no response after dropping it off. Then I call to see what the issue is, they tell me they ordered the abs module and it came in wrong so they ordered another one. After some time they called and said that the module on the recall did not fix the issue, they needed to put a new master cylinder on it for $380 and it would fix the issue, I told them to go ahead since they had installed the abs module for free. Several days go by and they call me to tell me that the master cylinder did not correct the problem that I needed new calipers all the way around for a cost of over $1900, to which I declined. Technicians are supposed to be experts, not expensive parts changers. I picked up the car and the brakes were worse than ever. Having a mechanical background myself I decided to diagnose the car further which I should have done in the first place. Using a brake pressure gauge I determined it was the left rear brake caliper. I replaced one caliper for around $80, bled my brakes and the problem is solved. I should have repaired it myself to begin with. When I saw the recall and how many vehicles had the same problem, I wrongly assumed the recall would fix the issue. I hope this helps someone with the same issue. 

[bbf2530]

12 minutes ago, Farmer Dunn said:

Ford has a recall for the excessive brake pedal travel, however they don't know how to fix their own problem. My 2009 had that issue, the brakes went almost all the way to the floor when stopping. I bled the brakes multiple times, computer bled the abs module, replaced rotors and pads, because they were below spec, and still the same issue. While researching for answers I came across the recall. I called Gateway Ford which offered to fix it for free under the recall. Over a month goes by with no response after dropping it off. Then I call to see what the issue is, they tell me they ordered the abs module and it came in wrong so they ordered another one. After some time they called and said that the module on the recall did not fix the issue, they needed to put a new master cylinder on it for $380 and it would fix the issue, I told them to go ahead since they had installed the abs module for free. Several days go by and they call me to tell me that the master cylinder did not correct the problem that I needed new calipers all the way around for a cost of over $1900, to which I declined. Technicians are supposed to be experts, not expensive parts changers. I picked up the car and the brakes were worse than ever. Having a mechanical background myself I decided to diagnose the car further which I should have done in the first place. Using a brake pressure gauge I determined it was the left rear brake caliper. I replaced one caliper for around $80, bled my brakes and the problem is solved. I should have repaired it myself to begin with. When I saw the recall and how many vehicles had the same problem, I wrongly assumed the recall would fix the issue. I hope this helps someone with the same issue. 

 

Hi Farmer Dunn and welcome to the Ford Fusion Forum. This does not seem like a Ford issue. It seems more like a dishonest Dealer Service Department issue.

 

It sounds as though they did not even explain or perform the ABS recall correctly. They needed to flush the old DOT 3 fluid out of your brake system. Then refill with new DOT 4 fluid. Then test the ABS HCU (Hydraulic Control Unit) to see if it needed to be replaced. If the HCU passes, the recall is complete. If it fails, it needs to be replaced.

 

From what you have described, it seems as though for some reason they decided you were a good candidate for ripping off.  Just the "You need all four brake calipers replaced for $1,900..." spiel points to that.

 

You may want to find a new Ford Dealer to have your car serviced at.

 

Let us know how you make put and good luck.