1990 4Runner braking problem

Belrix

New member
Hi all, first posting.

It's a 1990 4Runner with 240,000 miles, auto-trans, v6 3.0 engine. It was recently, heavily rebuilt (engine, trans, suspension), by the previous owner and then sold to me about a week ago.

This Saturday, I was driving up the mountains for the first time since I've gotten the car. The engine is small so I spent a lot of time downshifted and climbing slowly up the mountainside (to 9300 feet alt).

I was following another vehicle and when we got to the top, the vehicle in front hit their brakes for some reason. I went to hit mine and "Whoops!" the pedal slid nearly effortlessly to the floor. I swung right, along-side the car and kept pressing the brakes. When the pedal was nearly at the floor, the brakes grabbed, I slowed quickly, and I pulled back into my lane.

When I reached the top and the engine dropped back to a more normal RPM, the brakes returned. A couple times this happened. When the engine was laboring for a longish period of time, the brakes would go away then return fairly quickly as the average RPM dropped back to normal. They seem to come back pretty quickly - in a mile or two.

The 4Runner has a history of a slightly squishy brake pedal but this seems ridiculous. The brakes work find down here in the "flats". No problems at all.

I asked a mechanic friend at the mountain top (group camping weekend) and he said that he thought I was losing my master cylinder. If it heats up, as the engine is working harder, then the braking strength drops. When I returned to a more normal RPM, the master cylinder would cool and brakes would return. He said if it was a vacuum leak, then the pedal would get hard, not soft.

The brake fluid is full, even slightly over the "Full" line but not badly so. Also, FWIW, the engine runs a little hotter than normal because the previous owner replaced the overhead cams, breather, & exhaust manifold with "performance" parts.

I came down the mountain two days later with no problems. This, of course, is the easy direction. I tend to downshift to slow as a practice as to not overwork the brakes. It's a pretty standard trick here in Colorado.

So - any other theories before I drop $130 on a new master cylinder?

My working theory, by the way, is that the brake fluid is old and it's boiling. Maybe replacing the fluid with some high-temp stuff is the right path.
 
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Shoot the mechanic. Don't replace the master-yet.

When you run the engine hard, your throttle is open for long periods and you will lose engine vacuum. If heat on an unused brake system causes the go away, it probably is heat causing the brakes to boil under continuous downhill loads.

You, I think, Have a problem with your vacuum assist (I have the same truck,and am here in colorado too!)

If you have performance parts, then probably the previous owner was lying. I've looked for performance parts, and haven't found any. Plus, with performance parts, you should go up that mountain just fine. Mine does, stock (albeit out of overdrive)

I would recommend
Check the check valve in the big vacuum line that goes to the vacuum assist. It is probably shot.
Bleed your brakes. change all fluid.

Also, do you have headers(the exhaust manifold you mention)? Are they touching the brake lines? That is the only way heat of climbing could cause brake failure.
If so.. Jee, what bozo did that job?
 
Just a quick revisit.

The new brake fluid (DOT3) seems to have done the trick. I tested on a local large hill & the brake fade is gone.

The Brakes Plus store says my rear brake cyclinders need replacing (fluid leaks when the boot is pulled back) and the rear axle seal on one side. I'm going to put that all off for later.

Anyway - things are better.

Now just get the air-conditioning charged & replace the dead radio and I'll be done for a bit.
 
Just fyi,
A friend had a real similar problem. On road his brakes were fine. Offroad his would go the the floor on the first press of the pedal.
Turns out his wheel bearing was bad and the "slop" in his bearing was allowing the rotor to push the caliper pistons back in. THis would only occur on rough terrain while moving slow. The first push of the brake pedal would push the pistons out, the second push would stop him.
 

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