2007 Navigator No Brake Fluid at Caliper

Rowekmr, what you are missing is that there can be other flexible lines besides just the hoses that go to the calipers. The caliper hose goes to hard line, but then you need to follow that hard line to see if it transitions to hose and back to line again somewhere. THAT may be the hose that is giving you issues. Re-read whjco's post.

I done a few brake jobs but this work is being done by a Ford tech who helps me out on his off time. He is not the master brake mechanic though but he's been working on cars for awhile.

He says he only has seen a blockage like this once so I took it to a local shop that does a lot of brake jobs to see if they can diagnose it. My buddy does side work but this looked like a long tedious job so I passed it on to a shop.

The brake pedal is firm and doesn't go to the floor like a Mountaineer we just repaired which needed a new ABS/HCU pump but that's another story lol

The truck stops normal from 0-40mph above that you can detect the truck pulling to the left when you brake hard.

BenK wrote:
Assume you have worked on brakes before and pretty much know what you are doing...if not, suggest going to a ASE Master Brake mechanic

Also assume you are waiting for the caliper & hose to fill up with brake fluid...then it will flow out the bleeder

Is the brake pedal going to the floor? Or is it stopping firmly?

If stopping firmly, there is a blockage

If going to the floor, the fluid is going somewhere (assuming the MC is in good condition)...like filling up the caliper and hose...

We traced the brake line from the caliper to the ABS/HCU and it was all hard line. The lines are not out in the open and wondered if the blockage could be in the ABS pump or Master Cylinder so I decided it's a job for the pros or as another poster stated a Master Brake Tech.

BurbMan wrote:
Rowekmr, what you are missing is that there can be other flexible lines besides just the hoses that go to the calipers. The caliper hose goes to hard line, but then you need to follow that hard line to see if it transitions to hose and back to line again somewhere. THAT may be the hose that is giving you issues. Re-read whjco's post.

Usually if a caliper is hanging up which is unlikely since you have a new caliper and brake hose, you'll feel it at all speeds and the bad one will be opposite side of the direction it pulls when you hit the brakes.
I can't explain why it won't bleed, but if it stops straight and well at lower speeds, and is only pulling a bit, tires might be suspect.
Maybe try swapping front tires side to side.
I had a recent situation where rotated tires back to front on the old Dodge, tires like new still, truck acted like alignment was bad or a caliper hanging up a little. Pulled slightly while driving and pulled harder while braking at highway speeds. Brakes weren't hanging up and alignment was good. Swapped front tires side to side and the issue went away.
Can't explain it, but that was last year and the truck still drives and stops straight. Tire appears to have zero problems. No vibration, no bulges, nada.

UPDATE:
Shop diagnosed a bad ABS Pump aka HCU. I just changed on in a Mountaineer so didn't think it could happen again. I actually didn't believe the shop but gave them the go ahead.
New the HCU was 800 my cost (1,000 retail) but the shop found a good used one locally for $75 and installed it and bled the lines. I was told on the Mountaineer that the ABS pump needs to bled itself with Ford software but this truck stops fine.

Only issue is if it sits for awhile and is started the ABS light comes on but all other starts for the day it stays off. Shop manager when told of this believes the ABS module needs to be programmed (they did on the Mountaineer).

I will find out about the programming later this week.

rowekmr wrote:
UPDATE:
Shop diagnosed a bad ABS Pump aka HCU. I just changed on in a Mountaineer so didn't think it could happen again. I actually didn't believe the shop but gave them the go ahead.
New the HCU was 800 my cost (1,000 retail) but the shop found a good used one locally for $75 and installed it and bled the lines. I was told on the Mountaineer that the ABS pump needs to bled itself with Ford software but this truck stops fine.

Only issue is if it sits for awhile and is started the ABS light comes on but all other starts for the day it stays off. Shop manager when told of this believes the ABS module needs to be programmed (they did on the Mountaineer).

I will find out about the programming later this week.

It should stop fine now. But if you activate the anti locks it will introduce air in the system.