Overheating brakes

Tiny
DRHENRY
  • MEMBER
  • 2000 DODGE CARAVAN
  • 2.4L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 185,000 MILES
I have the van listed above base model. All 4 brakes drag and overheat intermittently ever since I had the power brake booster replaced recently. Some months ago I also had replaced the front brake pads, one of the calipers, and both front brake hoses, so those are unlikely causes.

The brakes do not drag at all most of the time. I am usually able to roll the car in neutral without restriction. So far, the brakes overheat and start to seize only when I drive at highway speeds in the mid-afternoon when ambient temperatures are around 90, (and only westbound--weird!). I haven’t done any more braking than usual when they start dragging and overheating. Pulling over and stomping on the brake pedal a few times seems to unlock it.

The mechanic did not measure the push-rod or compare it to the push-rod on the old booster. He said replacement boosters were factory preset and that he never had to readjust a replacement booster. He claims the problem is more likely in the ABS or something else.

On the other hand, I wonder if the push-rod is just a fraction too long, but not long enough to cause dragging at normal ambient temperatures, and if high afternoon temperatures maybe heat up the master cylinder just enough to increase pressure in the hydraulic system to make the brakes drag.

I plan to get a $15.00 H-tool for measurement, take the master cylinder back off, and measure the push-rod to see if it is too long and needs to be readjusted. I have to remove a lot of stuff to get at it, so if there is a possible simpler solution, I’d like to hear it.
Does anyone have any insights or suggestions?
Sunday, September 22nd, 2019 AT 8:41 PM

3 Replies

Tiny
94 TRANSAM
  • MECHANIC
  • 680 POSTS
Hi and welcome.

From what you describe it sounds like the booster vacuum check valve may be hanging up. If it sticks open it will apply vacuum and apply the brakes. This is probably why stomping on the brake fixes the issue. I would suggest replacing that and see if that fixes your issue.

Rich
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Sunday, September 22nd, 2019 AT 10:57 PM
Tiny
DRHENRY
  • MEMBER
  • 2 POSTS
Insufficient pedal free-play was the most plausible explanation I've found so far: http://cf.linnbenton.edu/eit/auto/krolicp/web.cfm?pgID=7736&fbclid=IwAR30ywzy3UVHLTLB2Bmw8GPxNkwtyA5jGYzSVgAx4RAyZCXBZ-bd7_m-B2I
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Tuesday, September 24th, 2019 AT 9:47 AM
Tiny
94 TRANSAM
  • MECHANIC
  • 680 POSTS
It is possible, but if that were the case it would likely happen all the time and stomping on the brakes would not free it up. Because stomping on the brake would not make the rod shorter. Unless there is more to your issue that is unsaid I would look at the check valve.

Rich
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Tuesday, September 24th, 2019 AT 3:32 PM

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