Hi All

96 Exp Sport - just did the brakes, but now I get a constant drone sound, and really loud at about 65 MPH

I did the Driver's side first, was late, so waited to do the passinger side couple days later, she drove it about 50 miles - no issues at all...

Then, when I pulled the pass side, the lower slide was just frozen, would not move at all - had to use a screwdriver and a small sludgehammer to get it loose, after trying to soak it with PB blast, etc - finally after an hour, it broke loose, and I was able to get it out...

I couldn't get the caliper bracket off the spindle (these are the front brakes BTW) - tapped it with a hammer, soaked it, waited, still wouldn't move even tapping my 15mm box end wrench with a hammer... nada...

so, I had to leave it on the wheel...

the inner surface is pretty bad, and the inner pad was shot for sure, the center of the rotor was rough, and not smooth. the outer only about 1/2 warn. I had no choice, I had to reuse it, so I put it back together with brand new pads (ceramic) and all new hardware, etc...

but now, I get a droning hum at almost all speeds... almost like a bad wheel bearing noise...

The wheel on the pass side spins freely, and the drivers side has a spot where it is hitting something at one point...

any thoughts as to what is causing this? - it was perfect until I did the pass side brakes (but didn't replace the rotor, couldn't)

Thanks all

 

Does the noise change when you apply the brakes? Did you maybe bend the dust shield in all your pounding to where it is now rubbing on the rotor?

-Rod

 

I'm having a hard time understanding what you did, so let me ask if you beat on anything that transferred load into the bearings? Bearings don't do well when shock loaded. There are times when a BFH is called for and times when it is better left in the tool box. When working with bearings or anything that could load the bearings, finesse is called for unless you plan to replace the bearing as part of the job.

 

Is your Explorer 2WD or 4WD?

A caliper in a bind, lose caliper bolt(s) or a wrapped rotor can cause the noise.

Good pads on a warn rotor will bend the rotor under full clamping 'panic stop'

I Warped 3 out of 4 rotors on my 1996 5.0 AWD Explorer one panic stop after swapping pads.