I HAVE YOUR SOLUTION! After 7 sets of rotors (each cut once), 4 sets of pads, new hubs, and new calipers (twice) - I found the solution.
I have a 2001 Excursion, and have had this problem for ever, and have tried every brand of high end rotors and OEM rotors. Every 5000 miles, I still got a brake job.
Here's the problem:
Ford put 16" rims on the EX so they could clear a 7' garage door. Notice how all the new truck advertisements are about big huge brake systems, and have 20" rims on them? SMALL RIM = SMALL BRAKE SYSTEM. Big Rim = Big Brake System.
What's happening is the system is overheating because it's too small, and is overheating the DOT3 brake fluid. The fluid is boiling, causeing the caliper to sieze on the right side, and sometimes the left. Mine was on the right more often. When you go to a shop to have the brakes looked at, their going to tell you that the right side caliper is siezed/frozen. Which it is, but relpacing just the caliper won't fix the problem.
After about $6,000 in brake jobs over 2 years, I had enough and did my research. Here's what you need:
2 new calipers - The right is siezeing, but like rotors, you replace these in pairs. 2 new rotors - don't go cheap, but you don't need the best. Buy a "good" set of rotors and pads. I bought from frozenrotors. Com. Read about them - kinda cool. 2 new front brakes hoses. The brake fluid overheating has broken down the rubber lining.
Now, most importantly, and fortunately the least expensive - Get the brake fluid flushed with DOT4 brake fluid, not DOT3. DOT4 has a higher boiling point, and won't overheat/boil, therefore, won't kill your new calipers. The DOT3 is boiling and killing the calipers, and thus - the rest of the system. Yes, DOT5 and 6 is even higher, but their synthetic, and you can't use synthetic in this system. It's will kill your ABS system.
Now you're telling yourself, this is going to be expensive! Well, yes it is, but you bought an EX, life goes on. You can go cheap, but learn from my mistakes. If you go cheap, you will keep replacing stuff.
I've had these brakes on for almost 20K, and no problems. I should mention I pull an 8000lbs 32ft camper w/ double slideouts, and a 9000lbs, 32ft boat.
On another note - get the weight distro hitch and sway bar for your new camper. Because the steering is already sloppy on the EX, you want that camper sitting tight on your hitch.
Saturday, March 20th, 2010 AT 5:48 PM