I've researched the posts about brake upgrades until my nose bled. They've given me a lot of good ideas, but thought I would post before I pulled the trigger.

I've got 5 4x4 Excursions. 3 with 7.3 diesels and 2 with the V-10. Miles ranges from 150k to 220k. An Ex is showing signs of needing new calipers as one is sticking at times causing it to pull when driving, and then when braking, pulling hard to the other side. Whatever I do to upgrade the brakes on this Ex will eventually be done to the other 4.

Here is what I am looking for (my priorities):
1. Upgraded stopping power over stock (don't need it to handle like Corvette, just better braking)
2. Lifetime warranty on as many of the parts as possible

Here is how I use the Exs:
1. 50% Highway
2. 10% Overlanding / dirt roads (nothing extreme)
3. 20% Towing (3k, 5k, 8k loads)
4. 20% Grocery getter

Avg payload most of time is 1.5k lbs (me, wife, kid, 500 lbs of bumpers and steps, 500 lbs of gear). For tires, I currently run 40s, 37s, 35s, and 33s, but plan to end up with 40s and 35s with 4-6" of lift. All have bags on rear and sumo springs on front. No performance mods other than intakes and exhaust.

I will do the install and maint. I plan on keeping these forever.

Anyone have experience with the EZ-fit nickel copper lines? They claim it will outlast stainless steel. Napa and others carry it as complete kits for the Ex.

Thanks!

 

My thoughts on lifetime warranty...parts are junk and not worth the time 99% of the time. I used to get the lifetime parts for my dentside and i was constantly replacing them over a quality part.

Have you looked into the SSBC kits? I feel like this is the only way you will notice a difference. I used to buy into all the performance pads/ rotors but they never made a difference, had a shorter lifespan, and were a waste of money....IMO

I've never heard of the ez fit lines and not sure why you need them unless they are rusting out. the only lines of worry are typically the rubber lines at the wheels. The hard lines usually last forever unless you live in the rust belt

I'm jealous that you have 5 Ex's...I have 2 going on 3 but they are not Ford
I've wanted an Ex ever since I first saw one at a show pre release, just wasn't ever in the budget
Not sure why they got rid of them, guess the expedition is enough for most

 

Well, for some reason I was thinking of replacing the entire brake line, but your raise a good point. Maybe I should only be changing out the section of rubber lines by the wheels. I'm in Texas so not in the rust belt.

 

Any “brake upgrade” calipers that you find that use the factory mounting brackets are just rebuilt stock calipers or knock off the same.
The SSBC 6 piston calipers have just about the exact same piston area as stock calipers, so real additional clamping force.
The only REAL brake upgrade that I have seen of the EX is from Wilwood and requires at least 20” wheels to fit the bigger calipers and rotors, it also requires spending lots of money.
The stock hard lines should be fine on a TX rig, but get under there and inspect them, especially at where they sit in the plastic clamps that hold them along the frame. Both Russell and Crown make 5 hose stainless braided hose kits, I used the Russells and had them installed for 80K + miles.
I has a shop install new front Raybestos pads during a state inspection and I really didn’t like them as they did not perform nearly as well as the factory originals that they replaced. I swapped them out way early with a set of the Hawk LTS pads and those performed even better than the stockers, but with a bit more dusting.
Have you flushed out the fluid on your fleet? The newest EX is over 20 years old now and well past the typical life span of brake fluid, it’s something that a lot of vehicles never have done and can make a big difference in braking performance if the old tired fluid has absorbed moisture from the air over the years.

 

@WE3ZS, are you saying the SSBC have more or about the same clamping force as stock calipers?

I remember seeing the 6 pistons, but can't seem to find them anymore online. Looks like SSBC only offers the V8 (8 piston model). Any thoughts on those?

 

There was someone the other day that posted about the SSBC calipers. I do not remember if it was here or another forum. They said the performance was way better and the kit was worthwhile. I'll have to see if I can find the thread and link it for you.

Typically larger diameter rotors with larger calipers is the most beneficial for improvement, but the SSBC is the only kit I've heard of that allows you to maintain stock wheels. I don't think the SSBC or Wilwood kits are cheap though, but you can't put a price on safety...and for your use, it might be worth it

 

I've found a few posts praising the ssbc kit as well.

As for not fitting stock 16" wheels, that's not a problem. I don't want to spend a fortune but willing to spend some.

Buying the best rotors, pads, calipers at Napa is going to run around $750 for the front with the lifetime warranty. SSBC fronts are $1,800.

Biggest factors for me is better braking and ideally lifetime warranty. SSBC doesn't offer the lifetime warranty. Still debating.

Anyone have experience with ebc or the powerstops?

 

Maybe they were the 8 piston calipers, either way the math worked out (math done by Pirate here on the EX sub forum) to be fairly equal to the piston area of the stock calipers, so no additional clamping force. The pistons have to get smaller the of them there are, it’s just math and physics that dictate the rules. Of course a larger bore master cylinder could help to produce more clamping pressure no matter which calipers are being used.
If the folks raving about the SSBC calipers changed them out from worn out pads and stock caliper and the installation included a fluid flush, new flex hoses and new rotors as well as the new SSBC pads, then yes, I would assume the braking performance was better, just not an apples to apples comparison.
There are “grippier” pads, like the Hawk LTS ones I installed, they do stop you quicker but at the cost of more dusting.

 

While the piston area could be the same, they are more wide spread. Could this apply more even pressure across the pads? possibly improving performance/ pressure?
I have run Hawk and Z36...I did not experience any benefits and there are also drawbacks..."performance" means shorter life and these performance pads also do not do as well braking until warmed up. there could also be more dust as they wear faster as WE3ZS mentioned.

I have also ran cryo treated rotors which have been the worst for me, drilled/ slotted rotors which can eventually crack. my last set were not wore out but started showing slight stress cracks from the holes. I currently run slotted rotors as they are supposed to help keep the pad surface cleaner/ fresher but i don't think they are necessarily better than a solid rotor.
One time I went with basic centric pads/ rotors and they had been just as good performance wise as anything else i've tried.

I have not tried EBC but they will be next. I imagine they will be similar to everything else but are a known good product

 

Ive got a set of the SSBC 8 Piston calipers on my rig. Im using EBC pads. Not sure of model/ type. This brake system was already on when I bought it. So I have no experience on what the stock brake system feels like. Ive had other full sized SUV's. These SSBC's work great though. Ive put them thru my own test in an attempt to familiarize myself with how much mass Im movin around when driving it. There's a street which has Id say 30-40 degrees of slope to it when entering the neighborhood where I live. Its about a city block in length. Ive come down it a good 30-35mph several times when there's no cars in front of me, and smashed on the brake pedal to see just how effective a $2K big caliper brake system is on a huge SUV. I dont have numbers for you but I will say they work very well if you need them. I'd say these are definitely worth the investment.

 

I have looked at options as well - I just had to do a roadside replacement of a rear caliper that blew out the piston yesterday! Honestly, running good pads w/ stainless lines at the wheels & good rotors have served me well. The problem is longevity. I have 18" wheels w/ 325/16-18 Duratrac tires (best BY FAR of anything I have run, very durable tires) and have plenty of stopping power. The problem is that calipers are all crap. I haven't had issues w/ rotors cracking, just wear. It seems the rear calipers have been my biggest problem.

What I WOULD like is pistons on both sides. The absolute number is not a crucial as having clamping forces applied to both pads. Never been a fan of the cheaper 'floating' idea. If someone made a 4 piston, same basic layout as the stock 2 piston it would be plenty good. I suppose the smaller ones have a bit of an advantage of spreading forces even more. Cost for the 8 piston calipers is just too much to me.

 

Wouldn't another "brake upgrade" option be to upgrade to a super duty axle so that you could take advantage of the new super duty brakes? I know that axle swap is more catered to improved ride quality and turning radius but I think improved braking was another plus. Not sure the cost in comparison to the SSBC calipers but just throwing it out there.

 

I have the SSBC V8s on my rear axles and Russell Braided Stainless all the way around. Big improvement over stock. The biggest performance increase in my opinion is the increased reliability of the pistons and slide pins. Having more smaller pistons and a quality machined made in America brake kit as opposed to a reman means greater reliability. This solved my original issue of the rear pistons getting cocked sideways in the bore and dragging, even after multiple resets. Each brake piston is responsible for less braking force since there are 4x as many over stock. This translates to less wear on each piston, which should increase the serviceable life of the pistons/caliper. I do not tow so I cannot speak to hauling heavy loads but SSBC does fine in highway/street applications. I absolutely plan to put them on the front and I expect even better performance than what I have now. They are definitely pricey, but the way I see it is; buy once, cry once. Besides our 20+ year old trucks need the TLC invested in them to keep them on the road. It is simply the price that is required to maintain/upgrade our Exs. Still cheaper than buying a new 3/4 ton truck.