Brake Drags Overheats - solved - Flex Hose restriction
[ As well - Vibration on Highway - due partly to tie rod ends - but brake drag too. Double issue ]
Bump Thread - So I saw and read this thread and it helped me solve my problem, along with a really good You Tube Video - which I will share link to below.
So I will share - could help others.
Problem: One front disc brake on the 2000 Taurus would Drag and Heat up / even overheat, start to smell and burn - but only sometimes. Intermittently. And Vibration on highway. Thought only caliper, or tight slider pin ... but no - more - read on.
As well - VIBRATION on the highway at speeds over 80 Km/h, as that brake dragged a little / but would free up after short time, on the highway. (Vibration was also made worse by tie rod ends getting a little loose, replaced w/new tie rod ends, inner/outer both sides - and aligned recently - helped solve most of vibration - but not all. Brakes drag too. Suspected / Checked Tire Balance too - but that was good. )
And just changed the brake pads and had the rotors expertly machined with a new caliper too on that side.
Sliders / Slider pins were good and free now too, confirmed - having just done the front brakes and checked myself.
Calipers and pistons were good - moving - confirmed - cleaned up of rust and freed up, and confirmed pistons moving, with clamp push back - but that one front disc brake that was dragging and overheating - sometimes - seemed a little more difficult to push in with the clamp, so I had my suspiscions already on that side.
After some test drives - inspecting - it was clear one front disc was getting noticeably hotter than the other as well.
After another test drive, heating up way too much again, and even glowing dull red hot (! yikes) (seen best at night in the dark). Smoking a little, stinking, cooking good sometimes / sometimes not, and the whole wheel hub on the outside, obviously pretty hot. But only sometimes. Hmmm.
... finally determined - I still have a problem. Need to find it and fix it.
I HAVE A DEFINITE PROBLEM.
Did research here on this Forum and online, and found Video that led
me to the EXACT problem.
FLEX HOSE BEING PINCHED BY STEEL CLAMP / HOSE SUPPORT EXACTLY IN THE MIDDLE OF THE FLEX HOSE - THAT HAD RUSTED INSIDE THERE OVER THE YEARS, AND AS THE RUST EXPANDS INTERNALLY IN THE CLAMP, SQUEEZES THE FLEX HOSE ALMOST SHUT AT THAT SPOT - SEVERELY RESTRICTING THE FLOW BACK OF HYDRAULIC FLUID - WHEN YOU RELEASE THE BRAKES - THUS KEEPING THE PISTON UNDER PRESSURE FOR TOO LONG AFTER YOU RELEASE THE BRAKES. ACTING LIKE A ONE WAY VALVE WHEN YOU DEPRESS THE BRAKES. FLUID AND PRESSURE IN ... BUT NOT OUT / OR OUT VERY SLOWLY.
Check out this You Tube Video - this was my exact problem:
[ copy link into new browser window minus asteriks / without the stars ]
It would do it mostly in the city, when you apply and release the brakes more often.
It would release very slowly, long delay, as the fluid slowly flowed out, with great restriction, due to the pinch / blockage. And during that time - keep heating up more and more each time. And as the disc expands as it heats - dragging more and more making it worse.
Solution: Open up the clamp "loop" by prying carefully with various tools: large screwdrivers, small pry bars, vice grips, prying / levering against each other. Then, when clamp opened up enough, slide out flex hose from clamp, then wire brush crusty rust out, and then file out rust inside loop of clamp, with round file, then put together again, and clamp carefully with vice grips again, careful not to over clamp the flex hose at that spot / careful not to restrict again - but just enough to hold the hose enough as intended, and give the support / hose guide / support as needed again.
Then re-test. Go in car, apply brakes, go back to wheel and try rotate / to spin back and forth, see if free's up right after brake released - without "DELAY" .
Then test drive again. Highway and city and stop and check if heating more than other side again.
Yes - that was exactly the problem, and I fixed it, did not even have to disassemble any of the Hydraulic lines at all. Looking at it - I could tell that was probably the issue. Yes.
I will have to check the other side - at some later time - and maybe do the same "service".
Yes - I am in a rust belt area - where they throw road salt in the winter.
Yes - I drive this car in winter.
Yes - The car is old with many miles - near 20 year old car with near 285,000 km now.
So we start to see these sorts of problems now.
RUST - seems to be the cause of MANY of the problems I encounter on this older vehicle.
( ex. recently - rusting hose crimps / steel tubes on cooling system lines - on firewall, leading to heater core)
Fascinating problem - the way this develops. I never would have believed it.
Hope this helps someone else.
And the guy that produced that Video - deserves positive feedback - for clearly explaining and showing the problem.
Thanks all . Another (serious and important) problem fixed.