I recently emailed this thread to the service writer at my local Ram dealer. It resulted in the brakes finally working properly although somehow now the electric side of the ABS is now bad but no parts available. Here's the background.
I went to Firestone to get a new set of tires. My brake pedal had excessive travel for about a year and I noticed that they advertised doing brake work. I asked them if they did master cylinders since I suspected mine was bad. They said they did do master cylinders as well as the other brake components. I told them to go ahead and do the tires then check out the brakes. They later sent me pics via email showing me the pads and rotors needed replacing as well as the brake fluid. They said they would have to replace those before they could determine if the master cylinder was in fact bad. I said go ahead and replace the rotors and pads ($1100). They then notified me that the master cylinder and booster were bad. They replaced them ($1200). I picked up the truck and drove it home (3 miles). By the time I got home, almost no pedal travel and brakes overheated and dragging. I went back the next morning and left it. They supposedly re-bled the brakes and said all was good. I picked it up and drove it home. Once again, overheated brakes and dragging and this time the check engine light came on (ABS code). I called them and they said they had no idea why it was doing that but I could bring it up there the next week when their "master mechanic" came in. Apparently he is in their shop twice a month. I took it up there and left it. The next day they told me the ABS was bad and I would have to take it to the dealer. I went to the dealer and dropped it off. The next day the dealer called and said the brake fluid was contaminated and the hydraulic side of the ABS was bad because of it. They replaced it ($2000). They test drove it the next day and it still was dragging on all 4 wheels. They told me they were in touch with corporate to determine what might be wrong. A week later they called and said the calipers and hoses would have to be replaced. At this point, I wasn't sure what to do. I was fast approaching the value of the truck. I told them to go ahead and replace them ($2200). 3 days later I called them and they said the brakes were still dragging. By then I had come across this thread and emailed it to them. A day later they called and said my truck was ready and the brakes worked great but the ABS light was staying on. Since that part doesn't exist anymore, they couldn't replace it. I told them if the brakes work I don't care about the ABS light. I was done spending money. I'm into the brakes for $6500 as it is. Other than excessive pedal travel, there was nothing wrong with the ABS until someone worked on it. When I asked the service writer at the dealer about how they fixed it, he said the tech said something about adjusting the plunger rod which leads me to believe the problem started at Firestone. I apologize for the long discourse but maybe it will save someone unnecessary expense in the future.
