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Old 09-01-2017, 02:06 PM   #1
rick_ca
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Default 2003 Ion Brake Problems

Brake issue here so story so far brakes really soft so replace one rear cylinder and bleed in this order passenger rear, driverís rear, passenger front and drivers front. Clean new dot3 in all lines and brakes still soft so purchased a master cylinder and before installing bleed best you can do with the strange design of those things. Now brake pedal super hard and cannot depress it at all so also canít shift the auto gear shift, SO what have I missed or screwed up

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Old 09-01-2017, 02:46 PM   #2
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2003 L-Series 3.0L Sedan
Default Re: 2003 Ion Brake Problems

What does ".....bleed best..." mean? With a new master cylinder, is there a lock or blocking device on the output ports or cylinder rod, preventing master cylinder piston travel until its removed prior to installation? Is the brake pedal cocked in such a way preventing normal travel?

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Old 09-01-2017, 03:58 PM   #3
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Default Re: 2003 Ion Brake Problems

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Originally Posted by fdryer View Post
What does ".....bleed best..." mean? With a new master cylinder, is there a lock or blocking device on the output ports or cylinder rod, preventing master cylinder piston travel until its removed prior to installation? Is the brake pedal cocked in such a way preventing normal travel?
No Lock on this master cylinder when I say ďbestĒ i mean bench bleed while trying to hold reservoir in approx. location as to where it is on car from cylinder and maintain liquid level while manually pumping piston

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Old 09-01-2017, 04:51 PM   #4
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2005 VUE 2.2L
Default Re: 2003 Ion Brake Problems

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Originally Posted by rick_ca View Post
Brake issue... Now brake pedal super hard
Is it the same way if you crack a bleed screw on the passenger front brake caliper?
Are yo u in the Rust Belt?

Look at the first fixed mounting point( on the body/frame) of the front flexible BRAKE lines to each caliper, Is it rusted at all?

CAn you rotate any wheel by hand in neutral/park brake off/ jacked up , of course)?

...
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Old 09-01-2017, 07:20 PM   #5
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Default Re: 2003 Ion Brake Problems

rick_ca, if you tried bench bleeding, unless your master cylinder is clamped into a vise or holding fixture, you may be feeling the return spring inside, preventing hand pushing the master cylinder rod. If so, mounting it in place on the car should allow in-car master cylinder bleeding after both brake lines are connected (loosening each one for bleeding before bleeding the rest of the brake system). Normal brake flushing/bleeding procedures are usually right passenger rear/left driver front (RR/LF), left driver rear/right passenger front (LR/RF). The basic brake system is divided into two halves. If one wheel leaks, that half of the brakes are lost but the other half remains in operation to bring a car slowly to a stop.

Re-check your mechanical connections of brake pedal linkage, rod to vacuum boost and master cylinder rod alignment.

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Old 09-01-2017, 10:51 PM   #6
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Default Re: 2003 Ion Brake Problems

Thanks for all the suggestions I just finished watching a Scotty Kilmer utube video which Iím going to try tomorrow and post the results

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Old 09-02-2017, 11:12 PM   #7
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Default Re: 2003 Ion Brake Problems

ok I screwed up on install found problem had to hold brake pedal in 1/2 way position then align before installing cylinder to firewall, i now have partial brakes and going to bleed all lines tomorrow.

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Old 09-03-2017, 12:41 PM   #8
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Default Re: 2003 Ion Brake Problems

Great progress! Owning up to mistakes and learning from them allows moving forward. Let us know your outcome.

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Old 09-05-2017, 05:17 PM   #9
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Default Re: 2003 Ion Brake Problems

Ok bleed the brakes no air in lines but pedal still feels spongy might have to bite the bullet and take to the shop and have them rip me

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Old 09-05-2017, 07:46 PM   #10
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Default Re: 2003 Ion Brake Problems

I will try to attach service manual. How to manual bleed drakes.
Attached Files
File Type: pdf brake bleed.pdf (112.9 KB, 3 views)

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