Updated: FIXED (?) New CALIPER, rotors and pads. Still HOT!!!

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TobyU

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Uneven wear on the Old Pad which probably was the outside pad and you mentioned on the new pad outside pad wasn't evenly worn indicates either something is caught sideways and not lined up or the caliper is not free to slide on both pins. Typically if a piston is sticking you will have inside pad wear and if the caliper is not sliding on the pins you'll have outside pad wear.
Inner and outer pads are often different and often only wear indicators on one so always make sure you assemble and the same way the old ones came off.
 

Expedition007

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We had troubles like this on an F150. I believe it turned out to be that the pads were ever so slightly different. All four at a quick glance appeared the same. Two of one style were installed on the left, the remaining were installed on the right. This configuration was making the caliper bind on the slides when the brakes were applied and not allowing the outboard pad to release from the rotor. After a stop or two once everything gets hot it would grab so hard you couldn’t turn the wheel by hand. We were about to change calipers also. I happened to get out my phone and google the problem. I ran across some TSB about the problem and took a closer look at brake pads... problem solved.
 

D-Cole

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x 2 on the brake line. This happened on my 03 and 09 expys. You can find a lot of similar stories on here about the front soft lines.
 

Plati

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x 2 on the brake line. This happened on my 03 and 09 expys. You can find a lot of similar stories on here about the front soft lines.
what happens with the brake line? I assume this is the final flexible rubber line?

I've heard of them rupturing & leaking , then you lose brakes.

I've heard of them collapsing inside. You hit brakes and one wheel is delayed due to collapse so you pull to the opposite side then recover back to straight. I think I have that now on my 2003.

Is another failure mode where the caliper is locked ON somewhat?
is that where it collapses inside, you step on brakes and they work fine but fluid doesn't flow easily back out when you let off the pedal so brakes stay on too long. That will only be a temporary situation, right. It will flow back out after you let off pedal?

thanks
 

TobyU

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what happens with the brake line? I assume this is the final flexible rubber line?

I've heard of them rupturing & leaking , then you lose brakes.

I've heard of them collapsing inside. You hit brakes and one wheel is delayed due to collapse so you pull to the opposite side then recover back to straight. I think I have that now on my 2003.

Is another failure mode where the caliper is locked ON somewhat?
is that where it collapses inside, you step on brakes and they work fine but fluid doesn't flow easily back out when you let off the pedal so brakes stay on too long. That will only be a temporary situation, right. It will flow back out after you let off pedal?

thanks
The internal failure is more common than external leaks. And yes after a few seconds it will release the pressure and the wheel will turn probably as good as the other one but every time you hit the wheel it sticks way too long and that will get excessively hot. It will also usually pull to that side.
One of the things you should check for anytime you have a hot wheel or uneven wear or pulling when you hit the brakes. You just need someone to push the pedal while you apply pressure to rotate the wheel. It should go back to taking the same amount of pressure to make the wheel turn as soon as they let off the brake pedal as it did before they pressed it. If there is any delay over like a quarter second then there's a problem.
 

richs fishes

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I'd also vote for the brake hose. Collapses internally preventing the caliper from engaging correctly and more importantly preventing it from releasing. I'd bet if you jacked the truck up you'd find the wheels spin freely. Have someone engage the brakes and I'd bet the wheels wont move. Release the brake and you should find 3 wheels spin freely again but you'll likely find one that wont spin for at least a second or two after the brake has been released. Thats what I encountered on my new to me expedition just a few weeks ago and I ended up doing pads, rotors, calipers and hoses at all 4 corners for peace of mind. Pay attention to the orientation of the hoses before you remove them! Otherwise you'll put it together and find the rear hoses rubbing the inside of the wheels and have to start all over!....or so I've heard.
 

rjdelp7

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File or grind the metal(burrs) on the pads, where they slide. They should fit loose, with no resistance and a tiny bit of slop. I had set of (cheap ceramic) pads so tight, I couldn't barley get them on. Buy better quality pads. I like Wagner products.
 

Richard Mickelson

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Your problem is the brake hose!! Change out both front hoses while you are at it. They do collapse and cause the problem that you are having. The same thing happen to my Expedition about a year ago! The hose collapses inside so the brake fluid is slow to return to the master cylinder causing the brake shoes to drag and wear out premature. Easy Fix.
 
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