FordExcursions.com Forums
Orf
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• Pittsburgh, PA, USA |
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• Registered on 8/29/2003 |
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• 143 posts |
• 1 Vehicle
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 Posted:5/7/2004 21:04 |
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Driving over to my friend's house tonight, I eased into the turning lane at about 30 mph. As I increased pressure on the brake pedal, I heard/felt a snap and the brake pedal went right to the floor. To make things even more interesting, there was a car stopped at the spot where I needed to turn and traffic on my right. Nowhere to go. With the pedal on the floor, and me shifting down through 3, 2, and finally into 1. I got the beast stopped with about 4 feet to spare. No skid marks on the pavement, nor anywhere else for that matter, but my heart rate did jump a few notches.
I pull into my friend's driveway and pop the hood. I noticed right away that the brake fluid resevoir was sitting cock-eyed. The cylindrical unit that the resevoir sits on, which I assume to be the master cylinder, is also sitting cock-eyed. The master cylinder, or what I think is the master cylinder, is held in place by two bolts. The one on the passenger side snapped, but the one on the drivers side was still intact. I pulled out the broken stud, with the nut either cross-theaded or frozen on the threads, and headed to the hardware store to buy a grade 8, 3/8" x 2-1/2", bolt and corresponding nut, to perform some field surgery until I can get it to the dealership.
I then discovered that the head of the bolt was either frozen to the bracket, tack welded to the bracket (highlt unlikely), or severely frozen in place. This made me think that it might actually be a stud from the mounting bracket, which would be a very poor design in my book.
So much for initially wanting to make this a short post. My question is: Has anyone had this bolt break before? Any thoughts on how to get the bolt head out? Take a look at yours before saying you would beat it out. It gets pretty tight in there.
Specs for my X: '04 PSD 4x4, bought 9/1/03, right around 21K miles. I only mention when I bought it to show that this is an extreme premature failure for such a bolt. |
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RS-TX
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• Little River, TX, USA |
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• Registered on 11/22/2002 |
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• 298 posts |
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Posted:5/7/2004 21:59 |
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Wow!  Did you have to change your shorts? As Bill Cosby said once, "First you say it, then you do it."  
I've never heard of this happening before, but you can bet I'll check my X tomorrow. Good luck with your fix. Boy, I bet that was a scary ride.
Rick
2004 VW Jetta TDI |
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JohnBoy
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• DFW, TX, USA |
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• Registered on 9/3/2002 |
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• 972 posts |
• 2 Vehicles
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Posted:5/10/2004 10:13 |
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My first car was like a third hand me down '52 dodge standard... (tells u how long ago THAT was !)had over 200k on it when I got it in 19 and 65 !
coming thru town one day to a stop sign with about 5 cars waiting... slowed and put my foot on the brake and I KNOW that car started going 30 mph faster when I hit the brakes and nothing happened 
I'm so glad my dad had taught me wheat the emergency brake was for !!!
I didn't car that it scared the HECK out of the women in front of me, but it skidded to a stop 
talk about an interesting drive home ?!?!
my dad was just happy that I didn't have a wreck !!!
2005 6.0L 4x4 Eddie Bauer Ex
2003 6.0L 4x4 Limited Ex - traded in (BooHoo )
"The Republicans should back off and let men marry men, women marry women, and legalize abortion. In three generations there would be no Democrats." |
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Rob H
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• Detroit, MI, USA |
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• Registered on 6/13/2003 |
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• 6 posts |
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Posted:5/11/2004 06:53 |
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Being an '04, you should have it towed to the nearst Ford dealership. Ford will pay for all costs. Don't mess with it yourself, from reading your post you don't know anything about brake systems. FYI - ALL master cylinders are attached to the brake booster via mounting studs/nuts...not bolts. |
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Orf
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• Pittsburgh, PA, USA |
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• Registered on 8/29/2003 |
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• 143 posts |
• 1 Vehicle
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Posted:5/11/2004 08:31 |
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| Quote: | | Don't mess with it yourself, from reading your post you don't know anything about brake systems. |
Ouch.
I was wrong, and I did say in my original that I assumed, and we all know what assume means. That platitude appears to have held true again.
What broke was indeed a bolt. It threads through the master cylinder, and secures the assembly on which the brake fluid resevoir sits. While I don't claim to know much, I do know that bolts typically have a hex head. The portion remaining in the master cylinder body has a hex head, and according to the dealership service department (where I did take it to have it repaired) that bolt is coated with loctite prior to assembly. Given the tight quarters, they said they wouldn't expect anyone to be able to remove that bolt without removing the entire master cylinder completely. Further, Ford does not allow for simply replacing said bolt (Ford's term, by the way). Rather, the entire master cylinder assembly must be replaced.
Now, if Ford refers to it as the "master cylinder assembly", perhaps you can forgive a layman for referring to it as the master cylinder.
The reason I did not have it towed was because this happened at 8:30 on a Friday night. The dealership was closed, and the entrance to the lot is blocked. Further, the service department is also closed on Saturdays. I decided to drive the 4 miles to my house with the hope that I could put a "band aid" on it until Monday morning. My post was to elicit ideas on how to remove the bolt.
I do want to thank you for pointing out my ignorance. The beauty of forums like these is so that the ignorant (like me) can be taught by the informed (like you). |
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JohnBoy
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• DFW, TX, USA |
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• Registered on 9/3/2002 |
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• 972 posts |
• 2 Vehicles
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Posted:5/11/2004 09:30 |
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he says tongue firmly planted in cheek....
2005 6.0L 4x4 Eddie Bauer Ex
2003 6.0L 4x4 Limited Ex - traded in (BooHoo)
"The Republicans should back off and let men marry men, women marry women, and legalize abortion. In three generations there would be no Democrats." |
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LANDYOT
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• Subscriber since 11/23/2003 |
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• Newport News, VA, USA |
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• Registered on 7/15/2003 |
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• 1,110 posts |
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Posted:5/11/2004 14:45 |
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Orf - You continue to amaze me. That was written very nicely. I doubt I could've been as tactful, or as polite. Your way with words makes me wonder if it's within your ability to tell someone to go to h@// while simultaneously making them look forward to the trip. BTW, I'm glad you didn't hit anything during your misfortune. Ken E. |
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Orf
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• Pittsburgh, PA, USA |
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• Registered on 8/29/2003 |
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• 143 posts |
• 1 Vehicle
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Posted:5/11/2004 15:05 |
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Thanks, Ken. I didn't want to come across as a jerk. I'm glad I succeeded.
Too bad my experience of designing and building intake and exhaust manifolds for Formula Ford type open wheel racers wasn't more centered on braking systems. If it had been, then all of this could have been avoided. |
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