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Originally Posted by KTMCanuck
Thanks f5fstop and the others for the questions and comments.
The brake failure was total. It was reported to Transport Canada who are continuing to monitor the issue as they didn't seem very convinced by the dealer's explanation when they called them. The dealer was of the opinion that air was in the system. They claim that the air may have been in the system directly from delivery and that it took sometime for it to make its way through the system. TC and I understand that this is an electro-hydraulic system. Luckily I was expecting it to occur as the pedal had felt strange as I left my driveway. Expecting that something might be wrong I hit the pedal and it gradually went right to the mat I took action by slowing down gradually and using the parking brake emergency brake to slow the vehicle. TC doesn't apparently buy the air in the system explanation so they were apparently still investigating.
As to the other question, the harness plug was apparently damaged during production which allowed the door side harness to fall into the door.
The sensor was replaced for the TPM
Oh I almost forgot about the rear brake problem. Needed to have the rear rotors machined as they were glazed along with new pads and claen-up of the calipers. I understand this is another common occurance.
Again thanks for the questions and comments.
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i have heard of one other vehicle that was delivered with air in the brake lines, but that was an immediate failure (less than 24 hours after delivery). I would also question the dealer on a vehicle with over two months on it. For a complete brake failure, the entire hydraulic system would have to bleed down. It can happen, but the chances are about a million to one. Godo thing you knew how to handle it.
Ok, harness plug...that's understandable, not good, but understandable. Probably someone forced it during assembly.
As for the TC, do you have the off-road package or the standard package? The Borg Warner cases are pretty darn robust, usually the problem with these is a noise can develop, but it won't affect operation. Early ones had problems with the transfer case control module (but now fixed) and the encoder motor (now fixed). (Not saying they still can't fail, just the likelihood is now random versus most likely.)