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Old 07-10-2010, 12:15 PM   #1
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Sticking Caliper

My neighbor in coastal central Maine (Tony) has a sticking RF caliper on his '02 Dually F-350 diesel truck. He pulls a 35' 5th wheel trailer. The rotor is warped. He had a caliper stick several years ago and Ford said it was "rocks" in the caliper. He also has had work done to the brakes recently.

My rig, a Class A MH on a Work Horse (WH) W-22 chassis, has a second NTSB recall ongoing now because of similiar problems. Our WH Bosch calipers have phelonic pistons swelling from water contamination in the brake fluid.

My question for our forum members is this-

Do Ford products have these plastic caliper pistons installed in them resulting in similiar problems? If not, is his problem an isolated case? I recommended an immediate fluid flush and fluid replacement.

Any suggestions would be appreciated


Max H,
2002 Newmar Mountain Aire, 37', 3778, W-22, 8.1 Vortac, Ultra Power upgrade, CAI (cold air intake), Taylor wires, colder plugs, Koni shocks.
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Old 07-10-2010, 01:51 PM   #2
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I am not sure about the plastic caliper pistons, but I have seen the rubber flex line from the chassi to the caliper internally deteriate and cause a caliper to appear to be locked up. Although I have only seen this in vehicles that are twice the age or more of this one.

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Old 07-10-2010, 08:20 PM   #3
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The most common cause I've seen is a sticking mounting bolt. If the correct kind of "brake grease" is used the bolt will not corrode and stick inside the mounting bracket. If no grease is used, or the wrong kind; this causes one pad to stick against the rotor.
2000 Winnebago Ultimate Freedom USQ40JD, ISC 8.3 Cummins 350, Spartan MM Chassis. USA 1SG, retired;PPA,Good Sam Life member."We the people are the rightful masters of both the Congress and the Courts - not to overthrow the Constitution but to overthrow men who pervert theConstitution. "Abraham Lincoln"
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Old 07-11-2010, 01:36 PM   #4
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Seems like I have read about a problem with the plastic (phenolic) pistons swelling and sticking. I would think the correct way to fix this would be to go to a 'brakes-only' shop and talk to them about replacing with metal pistons and new rotors--AND see what they say about a written warranty and reoccurrence.
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Old 07-11-2010, 01:45 PM   #5
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I have an 01 F350 SuperDuty 7.3 Diesel as a daily driver. The largest problem I've seen with my brake setup is not the rotors or the calipers but the slide pin mechanism freezing up and the clearances on these are so tight that if there is the slightest bit of rust or junk at the top and bottom of where the caliper fits onto the hub they will keep the pads on the outside 'hung' tightly against the rotor. I just tore mine all apart and used a wire wheel and a file to get rid of the junk and rust that lies underneath the area where the clips that hold the brake shoes in place are. I had to heat and beat out both slider pins, cleaned them up real good (used a shotgun cleaning kit to clean the slider pin bores) and replace the rubber weatherseal boots on the pins. Lots of wheel bearing grease in the holes too!
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