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This is really not a ford but it has the 7.3 in it. The front left brake was sticking because it only had one bolt in the caliper. (Very scary I know) I replaced the bearings, races, seal, rotor, caliper and pads with 2 new caliper bolts. Coming home today the breaks got really hot after break checking some dip****. Pulled the tire off and the hub spun fine then I pressed the brake, released it and then it wouldn't. what the heck. no air breaks. the truck is a international 4700, 2001 model.
I've seen the flexible rubber brake lines come apart inside and only let the fluid flow through one way. Acts like a check valve. Sounds like that's the only thing you haven't replaced, might be worth a try.
I see lots of problems with juice brakes on this class of truck . Hoses often ! . Calipers and slides also . If hot enough to smoke , replace the pads , hoses and calipers ( all ! both sides) on the front axle . Be ready to do the rears soon .