I have a 96 warrior, i tore it down completely this winter to weld the frame and paint everything. I have it all back together now, and the rear brakes are mush. I have bled them several times, and the pads have about 80% left on them. It recommended DOT 4 fluid, but I used DOT 3, could that be my prob?? They worked fine when I tore it down? Any help would be greatly appreciated.

 

Someone, please???

 

Does "I tore it down completely" mean the master cylinder was disconnected from the caliper, thus allowing the lack of fluid for a prolonged period of time (allowing the seals to dry out)?
Are you getting actual pressure at the caliper when you bleed (does it "shoot" or "dribble" out), or can you get pressure from the M/C without the caliper connected (or bleed pressure at the M/C)?
Could be that either the caliper or M/C needs a kit?

 

No, the master cylinder and entire rear brake system was left in tact, it was simply removed from the frame. When i bleed it, the fluid squirts out at a constant stream, it's been bled probably 4 times. The brakes do work, it's just that the pedal has to be fully compressed before they even begin to grab. They worked fine before.

 

A couple of things come to mind.
1. you mixed brake fluids that are incompatible. Now you need to replace that fluid with the proper fluid. Unfortunately you may need to relace all the rubber in that system. Eg: mastercylinder seals and plunger, caliper seals, and if a rubber hose then the brake line its self.
2. it is possible to have air still trapped. if it is spongy, then you either have air in the system, or the hose is bad.

If it were me, I would immediately get the mixed fluid out of the system. if still mushy, I would then use a mighty-vac to bleed the breaks. If that didnt work, I would fill a NEW oil can with NEW brake fluid and try to bleed the brake bakwards. remeber to remove the reservoir cap, and remove as much fluid as possible with a turkey baster. (this method works great on airplanes) Also do not let the reservoir overflow as brake fluid will make toast of your paint.

If none of the above work, then replace all the rubber in your system and put a teflon lined steel braided line on. Remeber, never ever mix brake fluid types. Different types require different rubber compunds, and as you have just found out, it can create major headaches when fluids are mixed.

3. If you are very luck, and I mean very lucky, it vould be something as simple as contaminated pads. but from your wording, saying you had to push all the way down to get braking action, I doubt it.

Hope this helps, and good luck.
Ron[img]i/expressions/face-icon-small-cool.gif[/img]Text