2002 Expedition with 100K miles. Heard grinding noise (never heard any squealling) when using the brakes and so immediately inspected the brake pads.

The driver side front inside brake pad was completely worn down, it was a little off, like maybe one of the calipers was sticking. The rotors appeared to be ok with no scarring or anthing that I noticed. At the time I decided not to replace the caliper, just put new pads on. Used the middle of 3 choices at the parts store.

As soon as I started driving it, still hearing a terrible grinding noise when putting on the brakes. Thought it could just be new pads wearing in, but after a couple of days it didn't go away to I pull off the caliper to replace it (front driver side only) like I should have done the first time when the wear indicated that it was sticking.

When I inspected the rotor, the back side (toward the motor) was scarred up in a couple of places pretty bad so I replaced the rotor and the caliper on then put the same pads back on. There is still a terrible grinding coming from the front brakes and it seems that the front drive side is where the noise originates.

Please help, replaced the caliper and the rotor, with new pads and still grinding, what could be going on here? Could I have gotten a bad set of pads? Could the pad thickness be off? Could the brake line be collapsing?

 

It could be the bearing inside the hub on that wheel that you're hearing, and not the brake.

 

Does it grind all the time, or just when you are brakeing? I know you said when you are braking in the first sentence, but this is critical I think.

If you are not sure, then jack up the front end and spin the tire. If it spins freely, with no "grinding" and no top bottom, or left/right play, then its unlikely that its the master cylinder, ABS (does it have ABS) or hub.

You are saying that NOW, you have a new rotor, new caliper and new pads and its still grinding? Does it pull to that side or the other side?

I am no profi, but we can at least try and think together....