Problem sticking caliper pistons 2006 F350 6.0 - Diesel Forum - TheDieselStop.com
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post #1 of 22 (permalink) Old 08-20-2019, 04:26 AM Thread Starter
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Problem sticking caliper pistons 2006 F350 6.0

Hello, I would like to buy overhaul kits for all 4 brake calipers for my 2006 F350 6.0 DRW. I had hot brakes on the front axle last year. I renewed the front calipers, now I have in front right again sticking pistons. The exchange calipers were from Raybestos and are badly made. I have an agricultural machinery workshop and have often overhauled brake calipers.
Only to get good parts for my SD is very difficult here in Germany. I am now looking for high quality overhaul kits. Thanks
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post #2 of 22 (permalink) Old 08-20-2019, 06:51 AM
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I usually stick w/ Motorcraft parts on the brakes. I am sure others have their favorites though.

Be sure to flush the brake fluid. Old fluid (especially if overheated) can contribute to caliper problems.

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post #3 of 22 (permalink) Old 08-20-2019, 12:38 PM
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Are you sure it isn't the slide pins that are sticking?
That's pretty common as well. Would be an easier fix. Replacement slide pin kits are available.

I agree on Motorcraft parts. I'd recommend contacting Autonation Ford White Bear Lake. They've been helpful, and could probably get the parts you need ar good prices. https://parts.autonationfordwhitebearlake.com/

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post #4 of 22 (permalink) Old 08-21-2019, 03:11 PM Thread Starter
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Brake Fluid ist brand new, calipers and slide pins are 18month old. Slide pins are ok. The pistons are very difficult to push back with large pliers. Under the protective rubber (sorry, don't know the word in english) you can see some rust. The pistons were unfortunately installed dry without lubricant, a professional does not do that. Calipers are overhauled from raybestos (Rockauto), but not well made. Therefore I would like to do now well myself with new pistons and new seals. I have done this many times with Mercedes-Benz Unimog calipers .
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post #5 of 22 (permalink) Old 08-21-2019, 03:29 PM Thread Starter
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The truck is not driven in winter/salt, it is a only summer driven camper vehicle. I am currently on a big trip around Ireland with it. I had to brake downhill with ~20mph shortly hard on a narrow pass road because of oncoming traffic. Arriving down the Pass Road I smelled the hot brake. Strange is also, it happened with the genuine caliper the previous owner also had same problems in front right side.
I had problems with hot calipers, 18 months ago the actual calipers were both fixed, I replaced them with those of raybestos.

Last edited by Hartwig; 08-21-2019 at 03:31 PM.
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post #6 of 22 (permalink) Old 08-21-2019, 08:18 PM
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That does sound like a bad rebuild job on the calipers if the pistons are rusty. BTW, the rubber part around the piston is called a boot. I've rebuilt the front calipers on my truck. Used Motorcraft parts on them. It was kind of a pain to get the boots in place properly. I'm sure there's a special tool to do that, which I didn't have.

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post #7 of 22 (permalink) Old 08-22-2019, 04:28 PM Thread Starter
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Do you know how the tool looks like? For the calipers I've overhauled so far , you don't need any special tools.
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post #8 of 22 (permalink) Old 08-22-2019, 07:05 PM
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The service manual doesn't show a special tool, so there apparently isn't one. It calls for a boot retainer, but I don't recall that there was one on my truck, just a groove that the boot fit into (with difficulty) at the outer part of the bore.

First truck -- 1929 Model A Ford pickup, restored from ground up. Wish I still had it!
'99.5 F250 PSD Supercab LB 4x4, ZF-6 w/SB Con OFE, 3.73LS, Boost & pyro gauges, Swamps S175/146 injectors, DP 80 HP Econo PCM (classic version
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post #9 of 22 (permalink) Old 08-26-2019, 10:39 AM Thread Starter
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The camper weight is 6.5 metric tons. the brakes are not the best, I think about installing better ones. Does anyone know better brakes?
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post #10 of 22 (permalink) Old 08-29-2019, 01:59 PM Thread Starter
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I've tested how the piston "grows" when it gets warm. Dry installed, they probably get stuck.


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post #11 of 22 (permalink) Old 08-29-2019, 03:23 PM
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Not surprising. Phenolic or plastic has a much higher coefficient of thermal expansion than just about any metal. The pistons on my calipers are metal, so they expand at about the same rate as the caliper bodies themselves.
You might try to track down some metal pistons. That may solve your sticking problems, or at least lessen it drastically. I don't know if they're available anymore, but the loaded rear calipers I got from Ford a number of years ago also had metallic pistons.

First truck -- 1929 Model A Ford pickup, restored from ground up. Wish I still had it!
'99.5 F250 PSD Supercab LB 4x4, ZF-6 w/SB Con OFE, 3.73LS, Boost & pyro gauges, Swamps S175/146 injectors, DP 80 HP Econo PCM (classic version
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post #12 of 22 (permalink) Old 08-30-2019, 03:18 AM Thread Starter
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I have not found a supplier for steel pistons yet . Phenolic pistons are offered everywhere
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post #13 of 22 (permalink) Old 08-30-2019, 03:18 PM
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I imagine SuperDuty Fords are like hen's teeth in wrecking yards in Europe, or I'd suggest harvesting some calipers off an older one with steel pistons.

First truck -- 1929 Model A Ford pickup, restored from ground up. Wish I still had it!
'99.5 F250 PSD Supercab LB 4x4, ZF-6 w/SB Con OFE, 3.73LS, Boost & pyro gauges, Swamps S175/146 injectors, DP 80 HP Econo PCM (classic version
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post #14 of 22 (permalink) Old 08-31-2019, 01:15 AM Thread Starter
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I'm afraid you're right. In Germany there are no SDs at all at scrap yards. The vehicles were never officially imported, so there are hardly any spare parts to get.
The calipers are from TRW. I donīt think the pistons were only used in these SD calipers. I would have to find out where they were still used. You can get the steel pistons for sure, but where?
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post #15 of 22 (permalink) Old 08-31-2019, 02:15 PM
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You might try a PM to FMTRVT on here. Jack is a brake expert, working in the industry for years, and he may have information for you on availability of steel caliper pistons as well as interchange.


Also read thru this thread for info. FMTRVT and Ford_doctor have weighed in with some good info.
https://www.thedieselstop.com/forums...elp-me-556113/
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First truck -- 1929 Model A Ford pickup, restored from ground up. Wish I still had it!
'99.5 F250 PSD Supercab LB 4x4, ZF-6 w/SB Con OFE, 3.73LS, Boost & pyro gauges, Swamps S175/146 injectors, DP 80 HP Econo PCM (classic version
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Last edited by klhansen; 08-31-2019 at 02:24 PM.
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