[jgoff78]

So I just had new calipers, pads, and rotors installed a few weeks ago, but I haven't driven the truck. On Friday I went to the next town to pick up some stuff to weld for a family friend and came straight home. NO PROBLEMS. Today I got in the truck to go to meet the Mrs. and before I even made it past the next house I could hear a grinding sound. I immediately parked right outside my house The sound was identical to the grinding I heard when the calipers had worn all the way through my brakes (they had seized and wore a hole in one). So naturally I called up the dealer that did the brakes, they sent a tech out to see what was up at my house and then took the truck with them. When I called just before they closed the service adviser said "There was a rock in your brake". That's it. Nothing more, no more detail, so I am confused. Tomorrow I will ask for more info but the only thing I can think is that it was wedged somehow between the rotor and caliper... Anyone heard of this. It was the right rear brake. I don't know if there is somewhere else it could have gotten in to, but more importantly how could it have happened. Any chance they screwed something up and are trying to cover their asses or have you heard of rocks in brakes? Thanks all sorry for the essay

 

[ford_doctor]

Actually, the rock wasn't between the caliper and the rotor. It was likely behind the rotor in the hub area and trapped by the backing plate. It is not too uncommon for a chunk of rust to fall off a rotor during a brake service and have a similar affect. Usually, you hear a pinging rattling sound as the rust or pebble bounces around. How did a pebble get there? There are gaps in the backing plate that will allow a chance for "something" to get back there. I wouldn't go looking to point fingers.

 

[jgoff78]

Thanks for the info! That's what I was looking for.

 

[ford_doctor]

I think it was also very nice of the dealership to send someone to your home to check it out for you.

 

[LMJD]

I'm with Ford Doctor, seen it many times, a pebble gets behind the backing plate and makes all kind of noise.

 

[fireguywtc]

I had it happen to me on my 07. I had a rock land in the space between the dust cover (backing plate) and the rotor on the front. It made a horrible noise. I got under there and looked real good and found the culprit to my relief it wasn't something worse.

 

[LMJD]

Scuze me, I meant dust cover, not backing plate.

 

[jgoff78]

Thanks all. I heard from them today, and they said while there was in fact a rock in there, it was not the problem. After disassembling the right rear brake they found the parking brake had corroded and come apart. They checked the drivers side too and said it will shortly. It looks like they need to replace the entire parking brake assembly and said it would run $900 with parts and labor. I miss having my shop :'(

 

[Bill1013]

Thanks all. I heard from them today, and they said while there was in fact a rock in there, it was not the problem. After disassembling the right rear brake they found the parking brake had corroded and come apart. They checked the drivers side too and said it will shortly. It looks like they need to replace the entire parking brake assembly and said it would run $900 with parts and labor. I miss having my shop :'(

WHAT? on an 05, and they just redid the brakes. Seems to me like somethings up. $900 for that. I sure as hell would take it someplace else. My 99 EM brakes (parking) are no where near in that shape, even after my GF has driven with them on several times, yeah actually smoked them. From rocks to corroded, thats BS to me. In Ohio we use prolly more salt on the roads than you do in Utah.
EVER HEAR OF SECOND OPINIONS?

 

[jgoff78]

I wouldn't normally take the truck where I did, but the shop I take it to is about 60 miles from where I live and I didn't like the sound it was making. I didn't want to drive it down there and I wasn't going to pay $250 to have it towed.

 

[FMTRVT]

Actually, not that of an uncommon problem. And Bill, in Ohio you will get to know this joy.

The problem is that on the rear brakes the dust shield is used to retain the parking brake shoes, much in the same way a "backing plate" of a drum brake was. However these dust shields are not stamped from thick stock like a drum brake backing has to be, but it's two thin sandwiched sheet metal pieces. At our facility we thought they "doubled up for extra strength.

The however is part of the problem. With two layers it's easy for moisture and salt compounds to get between and not dry or wash out. The major issue happens around the shoe hold down pin however. It appears that the movement of the pin allows for any paint or corrosion protection to rub off and the subsequent rust around the pins weakens the metal to the point the hold down pin pulls though.

Usually when that happens there is enough damage to all the parts that the full Ford assembly is the best course of action, not a cheap resolution.

If you catch the problem before everything grinds itself to bits, you can get the backing plate and some hardware from Dorman (Rock Auto) and save big dollars. Not big labor however as the entire wheel assembly and knuckle still has to come off the axle.

I've got some pictures in my facebook page that reference the DIH brake if they will help.