Alright here's the situation. I came back form deployment six months ago and replaced all the fluids in the truck including the OEM brake fluid. Shortly thereafter, I replaced the upper and lower ball joints on both the driver and passanger side front suspension. However, when I reinstalled the suspension the coils did not seat properly and I had to R/R the suspension once more. This is where the brake problem begins. I originally installed the aftermarket front suspension and have R/R many components on it with no issues. However, this last time I was in a rush to get it done and had a friend giving me a hand. As I removed the driver's side he removed the passanger's side. During the installation he installed everything as I came behind him and torqued everything down.
After the install I took it for a test drive and everything seemed fine until I made a hard right turn into a parking spot or performed a 3 point turn at which time the brake pedal goes all the way to the floor. After a pump the pedal returns to normal. There is no evidence of leaks on the tires(caliper) on the three rubber lines, at the master cylinder or anywhere else. I have also put the truck on a lift and bleed the brakes twice also inspecting for a ballooning rubber line. Neither was an issue. Recently, I noticed that the drivers side hard line coming down from the master cylinder was sitting only about half an inch above the upper control arm. The hard line to soft line adapter was the culprit and once I tightened the frame mount down it moved the hard line out of the way of the upper control arm. This seemed to fix the problem for a bit and made me think that as the suspension compressed on the drivers side during a hard right turn the upper control arm was hitting and possibly pinching the line. However, after a day the problem returned. Since the truck is ten years old I am thinking about replacing the three rubber lines, the slide pins on the calipers as well as the hard line that got pinched in the event that there is a small crack at the flare inside the nut (no fluid leak though). Does anyone have any ideas as to why it only happens on hard right hand turns(again brakes are fine under normal driving) and any suggestions as to troubleshooting the brake components to isolate the problem?
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