The Ford Explorer’s brake system is a relatively robust and trouble-free system. But, that doesn’t mean something can’t go wrong. The Ford Explorer is one of the most common vehicles on our roads. The system is a product of what Ford learned in the late 1990s about brake systems and what it means to customer satisfaction. It is a relatively robust and trouble-free system. But, it does not mean something cannot go wrong. The Explorer’s brake system has large enough rotors and pad surface to safely bring the vehicle to a stop and the rotors can last at least the first two brake jobs depending on the driver. The calipers can last more than 100,000 miles before they might require replacement.
Inspection
When you take the vehicle for the initial test drive, look at how the customer uses the vehicle. Look at the tow hitch to see if the customer uses their Explorer for towing. On the test drive, listen for any driveline noises. Many older Explorers are known for having problems with the differential, shafts and axles. The most common symptom is a binding or chattering front differential while the vehicle is turning or braking.
When inspecting the vehicle on a lift, take a close look at the upper control arm bushings. Many customers will associate the rattle and clunking worn bushings can make when the brakes are applied as a brake problem. Verify the symptom with the service writer or customer.
While performing a moderate stop, observe if there is any ABS activation. This could be a sign of erratic or weak wheel speed sensor signals. It might be a good idea to check it with a scan tool.
Look at the brake pads for any sign of abuse. Look for signs of rust jacking between the backing plate and friction material. This causes the edge lift and material separation. The customer may also notice noise and vibration.
Make sure to measure the thickness of the pads. The minimum thickness is 3mm, this is a lot of material to the naked eye. Ford specifies that the pads can not vary in thickness from inner-to-outer pad by more than 2mm. Also, Ford specifies that there can only be 3mm of tapered wear.
If the vehicle has too much thickness variation or tapered wear, it is a sign that there could be problems with the brake hardware or the caliper pistons. Our Explorer Sport Trac had tapered wear on the outer brake pad because the rubber bellows that cover the lower anchor pin were unseated and had seized.

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