WARNING: 3rd Gen Revised Front Brakes

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jglopic

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So, I am on my second 3rd Gen Expy (we like them and drive them hard). The first one we had, I did a brake job, and just like every vehicle I have owned, the pads were very distinct as to which was inside and which was outside.

Had to do the front brakes on my 2011 Expy EL over the Christmas/New Year's holidays. I was at my in-laws house and didn't have lift/jack/jack stands or a place to do the work. I called a friend of mine who has an aftermarket parts shop nearby, and he said his shop could do the install if I could get the pads and rotors.

Driving back home (1200 mile trip), I started to suspect the brakes were dragging. Then the ABS light, traction control light, and "Service AdvancTrac" warnings started to intermittently light up, finally coming on continuously (for the last 300 miles of the trip). I got home and checked the brakes the next day. They had definitely been dragging, and the outside pads were worn unevenly (top worn more than bottom). When releasing the brake pedal, the caliper pistons were not retracting properly. The brakes were so tight that you couldn't turn the wheel by hand without a 3 foot bar between the lugs.

I took it to a dealership near my house, and they investigated. Turned out that the whole issue originated because the pads were installed with the inside on the outside and the outside on the inside. The warning lights were because the heat had fried one of the wheel sensors.

So, be warned that the front pads on the 3rd Gen revised brake system (starting in 2010, I think) are capable of being installed backwards. There is very little indication as to which pad is which. And if you are going to pay someone to install them, go to someone who really does brakes. For what I spent on the original parts and labor plus dealership repair for my front brakes, I could have had a brake shop do all four wheels twice!
 

rayt

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i did my own pads in my 2011, i used aftermarket pads and ebc pads, there is no difference between inside and outside pads, i removed my oem pads/rotors at 5000 miles in my vehicle.
 

emtmark

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Bringing this back, I'm having the same problem, first the drivers side are the outside pad after I did the rotor and pad routine, think under 10000
Miles down to the metal 9eae7b3f8d2ea6e1f2df9b6a28b32809.jpg
d692603c90238993af53474054c98e95.jpg

So I blow it apart and grab new rotors and pads as I only have a few hours and won't have time to turn the old ones. Job goes like before I pay real close attention to my guide pins and clean and grease them because I think that's what's goofed the first job. Everything seems ok until we go for a test drive. Now the passenger side is dragging I can see it. Acting exactly like the op said and it was when I was tightening the guide pins to spec that it started to bind. So I blew it apart again cleaned and regressed everything. Flipped and reversed the pads and put some thick sharpie bands on the rotor surface to show exact wear patterns. Same shit happening. Pinching like a V. If this is true there is an orientation issue with the pads what is it and how can I tell?! My drivers side is fine and wife leaves tomorrow for a trip to Elko Nevada and I don't want. Fried abs system. Fwiw I had do some around town stuff to see if it was just pad break in and it's not I can lift the front end and kick the drivers around for a rotation but the pass side won't budge. ?!? Thank you all mark


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mrford60

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i just did my first replacement (pads and rotors) at 50k using ford pads, the pads were clearly marked inside and outside. had no trouble. drove it to indy and back with no problems.
 

RedExpy

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Mr. Ford... how expensive were the OEM pads.. .I will be doing mine soon.. i don't think I need rotors but hey..since I am asking on that .. whats the whole package? thanks!
 

Quique309

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i did my own pads in my 2011, i used aftermarket pads and ebc pads, there is no difference between inside and outside pads, i removed my oem pads/rotors at 5000 miles in my vehicle.
I too just did my brakes on all four wheels with ebc rotors and pads. I didn't see any difference between the inside and outside pads. It's been a few hundred miles and the brakes feel better than ever.
 

USMCBuckWild

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Bringing this back, I'm having the same problem, first the drivers side are the outside pad after I did the rotor and pad routine, think under 10000
Miles down to the metal 9eae7b3f8d2ea6e1f2df9b6a28b32809.jpg
d692603c90238993af53474054c98e95.jpg

So I blow it apart and grab new rotors and pads as I only have a few hours and won't have time to turn the old ones. Job goes like before I pay real close attention to my guide pins and clean and grease them because I think that's what's goofed the first job. Everything seems ok until we go for a test drive. Now the passenger side is dragging I can see it. Acting exactly like the op said and it was when I was tightening the guide pins to spec that it started to bind. So I blew it apart again cleaned and regressed everything. Flipped and reversed the pads and put some thick sharpie bands on the rotor surface to show exact wear patterns. Same shit happening. Pinching like a V. If this is true there is an orientation issue with the pads what is it and how can I tell?! My drivers side is fine and wife leaves tomorrow for a trip to Elko Nevada and I don't want. Fried abs system. Fwiw I had do some around town stuff to see if it was just pad break in and it's not I can lift the front end and kick the drivers around for a rotation but the pass side won't budge. ?!? Thank you all mark


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Look at all 4 pads. They appear to be identical, but 2 pads will have 2 "humps" on the outside edge of the pad frame. 2 will not have these humps. Pretty easy to miss since the pads are literally the same except for these humps.

The 2 pads with humps are the inside pad for each side.

The humps fit inside the maintenance view openings of the caliper when installed. If you put both "hump" pads on one caliper it will hang up and not function correctly, while the opposite caliper will appear to function fine.
 

emtmark

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lol I diddnt update but I did eventually figure it out, was total DOH moment. I got the clue when inoonend about four different brands of pads at the counter of the parts store and saw some packed left and right and other just stacked same shape with same shape.


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RedExpy

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I did the power stop heavy-duty kit from Rock Auto....love it.


Game... did you do just pads? Do you know what part number you used??? need to do mine soon and looking for part numbers before i go and order.

was it the PowerStop Evolution or the Evolution Plus?
 
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