Rear Brake Calipers

[blksn8k]

I have noticed that the rear brakes on my Gen 2 make a rattling sound anytime I go over even the smallest bump, and there a lot of those here in Ohio.:sad: I also noticed in another thread that another member mentioned that he had his rear calipers replaced because they were rattling. Is this a common problem on Gen 2's?



I need to take mine in to have another exhaust manifold leak checked before the powertrain warranty expires and will probably have the dealer at least confirm where the rattling sound is coming from. I am pretty sure it is the calipers as the noise goes away when I apply the brakes. I doubt the brakes would be covered under warranty since I am at about 56k so I would probably just replace the calipers and pads myself. The pads are probably due anyway since they have never been touched.

 

[blksn8k]

Decided to see what I could dig up and found this TSB on the brakes:



Edit: there should be no reason replace the calipers as long they are functioning properly. The reason for the rattle is that the original pads apparently did not have any anti-rattle clips. The replacement kit from Ford includes a metal strip attached to the outer pad on each side that forms a loop that takes up the slack between the pad and the caliper. With the old pads still on the vehicle and with the brakes cool I can actually reach between the wheel spokes and move the outer pad enough with two fingers to make it rattle.

 

[blksn8k]

Problem solved. Went to the dealer this afternoon and picked up Motorcraft brake kit BR-1109-B which is about $40 less than the kit listed in the TSB. You can also get the same kit at Rock Auto for even less. The new outer pads did have an anti-rattle strip that was not on the original pads. No more rattle. The original pads were not worn down to the middle groove which means they had more than half their life left at 56k. Kind of sucks to have replace them but I have had similar problems with brake pads on Rangers where they had to replaced long before they were actually worn out. One of their "better ideas" I guess. :banghead:

 

[Robert Caffyn]

Somebody sent me a copy of the TSB and I went in and talked to them. According to the TSB, the metal clips had to be removed(worn) and replace3d. BUT, the fix was to apply some RTV or whatever under the clip when it was replaced. Didn't cost me a dime. My service guy works with me for the most part. Bob

 

[blksn8k]

Bob,



Unless your outer pads have the anti-rattle strips on them I seriously doubt the RTV will be a permanent solution. The RTV only serves to glue the stainless steel sliders onto the caliper mounting bracket. My original sliders were not the problem. As a matter of fact, I had to use a screwdriver and a hammer to remove them. That's how tightly they were stuck on the caliper bracket. My guess is that I could have left the old sliders in place. I did use the RTV but I doubt it makes much difference. The sliders do little or nothing to take up any slack between the pad and the caliper or the pad and the bracket. Included in the instructions of the TSB it specifically states that the new brake kit is part of the fix. The kit includes new pads and sliders. It also states that the problem is that the original pads did not have the anti-rattle strips. The anti-rattle strip and the sliders are two different things. The sliders allow the pads to move in and out while the anti-rattle strip prevents the pad from moving radially. My original outer pads did not have the anti-rattle strip but the new pads in the kit do. You can see the anti-rattle strip attached to the rear of the pad through the wheel spokes.



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