2008 Limited with 62K miles last dealer service they told me rear brake rotors are rusting and should be replaced by next service. So I got new rotors and pads and set about doing the job on Columbus day. When I took the tires off I could immediately see that parts of the backing plates were missing and after taking the rotors off the pins that hold the parking brake hardware clips were just free floating because the backing plate had rusted out so bad and were basically disintegrating. I have done numerous brake jobs in the last 35 years and I have never seen backing plates that rusted. So I had to finish the job and leave the new E brake shoes and hardware in the box they came in so we can drive it. Called a mechanic shop near me that I have used and he said off the top of his head $1800, called Monro they won't give me a price, but said they'd beat any estimate. Called the dealer and they said $22 apiece for the backing plates and $200 to $400 per side for labor depending on how hard the axles come off. Amazing you have to pay anywhere from $800 to $1800 labor to have $50 in parts installed. Why doesn't Ford make a 2 piece backing plate or a 1 piece hinged design so they can be replaced reasonable since they are making them out of such cheap tin that they have to be replaced so often at such a high cost?!?! I am not even considering doing this myself though it is way above my skill level.

 

I have not looked at the design for the backing plates on my 08 Expedition and do not know what portions are required for fitment of any additional hardware, if any. Depending on those requirements, I'd simply notch the baking plate to install them without removing the axles. After they are on, you can then decide if the notched material needs to be re-installed and use some additional sheet metal and some rivets to put them back together or fill in the gaps. That is, unless you want to go through the hassle to pull the axles or pay someone else to pull the axles.

The basic function of the backing plate is to keep some road crud off the rotors and out of the friction surfaces. They also possibly protect some nearby suspension soft parts from excess heat. I don't think the backing plates on these trucks and SUVs do anything to distribute cooling air to the braking surfaces as they might on sport vehicles with brake cooling ducts.

Most of the late model cars and trucks use wheels with much bigger back spacing than they used to and that should help minimize road crud from getting lodged in the braking surfaces anyway. We do not have any protective plates protecting the outer surfaces of the rotors besides the wheel spokes.

 

I like the suggestion of notching the backing plates rather than taking the axle out. At $22 a piece it's worth the gamble I'm thinking. I will have to consider it. I also wonder what others are seeing from their backing plates Is it just endemic to the rust belt or do they melt away on everyone's truck?

 

Passenger rear backing plate





Passer rear backing plate lower




Passenger rear backing plate lower closer




Driver side rear backing plate lower




Driver side rear backing plate upper


Soe photos I took of the backing plates.

 

Wow that looks pretty rough, do they use salt on your roads? I just did the brakes on my 2010 with 75k miles and not a spec of rust. I think the idea of notching then has merit just make sure they are secure on there, I hate to think of all the damage a loose one could do going down the highway. Good luck

 

Just pull the half shaft and be done with it. You will have to pull the wheel bearing as well

 

Pulling shafts and wheel bearings is above my skill level. I have decided to have it done in a shop I trust and have an appointment to drop off Wednesday for a Thursday repair. Since the parts are only available from Ford the shop manager is letting me get the plates from Ford and they will install them along with the parking brake hardware I already purchased but was unable to install. They will only be charging me for whatever labor they perform. It will be worth the peace of mind for me as my wife and sons drive it more than I do these days.

 

Yours has drum brakes on the rear?

 

The parking brakes are shoes inside the drum in the center of the rotor.

 

Beat me to it David, that is the parking brake assembly.

 

Doh! Thanks.

 

You know they're so big at first glance they almost look like regular drum brakes. Easy mistake to make. BTW cost me $500 for labor to have the backing plates put on properly and the new parking brake hardware installed. Backing plates ended up at $64 from the Ford counter. Funny last week they quoted me $44 for 2 backing plates then when I went to order them they quoted me $64. Then they took 4 days to come in. Oh well they're done now and I am set for the winter.


They say my E-brake cable is stretched. Anyone ever hear of that happening?

 

Congrats on getting it all taken care of. Hopefully the new ones last longer than the original set or at east until the next owner.

Sure, I would say a stretched e-brake cable is possible. I know on my 66 Mustang there is an adjustment available to take up the slack. I have not messed with later model e-brake cables, however.

 

The e-brake cable has never really held tight since I've owned the truck. I never had the dealer look into it. I figured I would adjust it properly when I did the new parking brakes, which the shop ended up doing. They said the cable was adjusted as tight as it goes and still doesn't hold as tight as it should. There is some resistance when you press the pedal, but it goes all the way down without much resistance. It does hold a little, but it is easy to drive away with it on by accident until the car chimes. Also when parking on a hill you feel the car go forward after you take you foot off the regular brake pedal even with the e-brake on. My Dad suggested looking into some kind of a clamp to take up the slack in the e-brake cable. I will be looking into that.