In the past I've had brake problem svc calls and a previous tech had added DOT3 to the DOT5 (correct fluid). This results in "clotting" of all the components, master cyl., slave cyl., brake assy, etc.,. Flushing usually doesn't work. Every thing needs to be replaced, unfortunately.
Are you sure it is Dot 5? I need to know. Thanks
are you using dot3 or dot5 brake fluid, I am pretty sure this truck uses dot5.
easiest answer is to use a pressure bleeder.
one of the 'tricks" is to get a bit of hose and put one end over the outlet of the bleeder on the drive motor, and have the other end down in a brake fluid container, so that it bubbles out the air, but any back-flow will be brake fluid.
is the master cylinder adjusted correctly? there should be 1/4" of free play on the pedal. did it bleed ok? sometimes they lock up and you have to bleed at the master cylinder outlet port to get the fluid moving.
Anyone have a service manual for this unit?
If you dont get all those seat o-rings in perfect you end up with bleed by (replace as unit). Have you changed the master cylinder as well? I always change them both as a set. The added pressure from one new brake component will cause the other, unreplaced, to leak, possibly internally.
As for the spacer, is this the aluminum u-shaped spacer? You can remove the top of the motor and hope... or remove the whole motor and remove the lower bell housing (w/o ser# hopefully no encoder). Advice for the future (had this happen to me, LOL....now), fold and stuff a towel under the brush holders when working on the brake assy. or changing brushes...try finding a brush mount screw in the motor of a Raymond swing reach...added hours n hours.