Rebuilt Air Pack Malfunctioning!

[Junglemist]

I rebuilt the air pack in my Deuce and after putting it back in, brake fluid pours out the slobber tube by the air filter.

When manually bleeding the brakes with no air pressure, the fluid level rises in the tube as you bleed and will start flowing out after a few minutes of bleeding the wheel cylinders. If the truck is started, fluid will flow out once the air pressure reaches 45 psi or so without pressing the brake pedal. If the brake pedal is pressed with 30-45psi of air pressure, then fluid squirts all over the place.

I checked my lines and everything is connected correctly. So I took the air pack back off and took it apart again last night. Everything looked great. I put it back on and the problem is still there.

The vent from the master cylinder has been removed and a reservoir has been added under the hood, so the fluid can only be coming from the air pack.

Since the truck was not drivable I had to ride my bike 30 miles back in the jungle today!

I need some ideas as to what to try next!

 

[FMJ]

Try this thread:

http://www.steelsoldiers.com/deuce/10905-airpack-rebuild-add-pics-4-09-a.html

 

[dabtl]

You may have put the cups in backwards on the hydraulic cylinder. That is the most likely.

 

[Recovry4x4]

Somewhere I did a thread on this very topic and it covered the TM instructing you to put one cup in backwards. It was a sticky on the old site and seems to have dissappeared on this site.

Found it, here it is!
http://www.steelsoldiers.com/deuce/7623-airpack-rebuild-warning.html

 

[Junglemist]

I read that thread among others and was very careful to put the seals in the correct way. When I took it apart the second time last night I rechecked everything. I figured that would be the most likely culprit.

When I took it apart the second time there was brake fluid in all areas of the air pack. There was brake fluid at the light switch, trailer air line, air inlet, large air cylinder, etc. So something inside is not sealing I guess. Is it possible that the seals in an NOS rebuild kit could be bad? I checked the rubber seals and they looked and felt good.