Don't use the cheap pads, I did and they were throwing dust and gone in 6 Months.

Good thing I bought them and the rotors at NAPA. They replaced the pads with there best pads and they replaced my Rotors.

 

I put drilled Brembo rotors and Hawk brake pads on my Focus. The extra stopping power is great... once the pads warm up. Less brake dust from the Hawk pads too. The Brembo rotors are much nicer then the stock rotors on the Focus, which weren't bad for a "cheap" car. and me driving "spiritedly".

I just bought a pair of Brembo regular rotors from Ebay for $50 for the Aerostar. I plan on using the van for delivery purposes, we'll see how they do.

Anyone have any experience with the Ceramic-style brakes from NAPA or anywhere else?

 

I am in the process of replacing rotors and pads on my '97 Expedition, and my research suggests that more expensive, high-tech pads wear better, operate properly under a broader range of temperatures, more effectively insulate the caliper from heat, and cause less wear on the rotors, not more. The reason given for the latter feature is that high tech pads heat the rotor more evenly at a molecular level, distributing the braking friction evenly over the entire surface (at the mollecular level) and placing less localized stress on any given point at any given moment. Unless someone suggests a reason why this explanation is mistaken, I'm buying into it.

Aside from the foregoing considerations, using longer-wearing pads will almost always increase rotor life. For the brakes to work properly, the rotor MUST be surfaced each time the pads are replaced. Surfacing removes material, making the rotors thinner, and so, the more often the pads are replaced, the more quickly the rotors will reach the point at which they must be replaced due to material removal.

I agree that drilling holes in rotors is dangerous without a great deal of sophisticated research into metalurgy and other factors affecting the strength and heat response of cast metal parts. The holes provide gas and dust vents, but they also reduce the amount of metal available to absorb heat and the surface area of the rotor under ordinary operating parameters. Moreover, the holes can seriously degrade the structural strength of the rotor and create weaknesses that potentially lead to catastrophic failure.

According to the Brembo engineers, drilled and slotted rotors improve braking only in high stress applications (e.g., racing and towing). For the first stop from 60 or 80 mph, OEM rotors will perform as well because the properly maintained system will remain well within the design temperature range. Further, in modern ABS-equipped vehicles, the stopping distances are ordinarily limited by the tires and/or road conditions, not the brakes.

I conclude that if I want more stopping power in my Expedition, my only choice would be to invest in a $2,500 wheel and tire upgrade and a $3,500 front rotor and caliper upgrade -- and it appears that tires having a friction coefficient sufficient to make use of the brake upgrade would wear out in 10,000 miles under ordinary driving conditions.

Remember, Ford and GM and Daimler Chrysler invest billions in R & D, and while they have economic considerations, if there were something as simple and cheap ($5) as drilling holes in the rotors that would make a significant difference in real-world driving, you can bet they would do it -- for the sake of competition, if nothing else. In any event, I now question whether aftermarket companies really have the resources to do the type of research required to improve most OEM braking systems.

Everything is a trade-off, and so bigger rotors are not necessarily better. Bigger rotors that are also more massive could prevent the brake pads from reaching the temperature at which they operate best. Also, the rotational intertia of more massive rotors could degrade braking, and the additional unsprung weight could degrade the suspension's competence to handle braking on less-than-even surfaces.

Alas, it appears that I will not be able to transform the Expy's brake system into a sports car. I will be grateful for any and all comments, repartee, argument, or even bona fide information.

 

Fellas
Two things, bigger is better and if you are racing your Aerostar go with slotted.
Your best bet is to keep with stock high quality rotors and pads. If your into upgrading buy a rear disc kit from Ford. If your a do it your selfer, a set of Explorer or Ranger rears will fit. With a lil modding of your park brake. I'm replacing my rears out this summer.

 

Hi CdnSoldier:

Can you really have disk brakes in the rear? I'm in! Would you post pictures when you do it?

Thanks

 

I was hoping to race my Expedition . . . Oh, well.

 

Yes you can mod a set of disc for the rears. Ford has a kit 600$ Cdn. It will fit all 8/9 " Ford diffs. But if you look at the parts, their the same as on the Explorer and Ranger.

 

I think slotted or drilled rotors upfront could help the Aerostars braking tremendously and they just aren't for the track. I replaced the rotors with Brembo OEM style rotors and EBC SUV pads. I really liked the way they feel, the initial bite,etc.

But I fear after only 6k they are warped again. I did everything right, made sure the rotors were on the right side,etc. But whenever I come down a hill or make a lot of repeated stops, I get the tell-tale shimmy and groan of warping rotors.

I use the van for delivery purposes, so the brakes take a beating. And with Pittsburgh not being flat, brakes tend to age faster here then in other parts of the country.

I don't know whether it was the pads ( too agressive?) something else on the van, the rotors being defective or what, but 6k on rotors is ridiculous, even with hard driving.

But back to my point. I have Brembo drilled rotors and Hawk pads on my Focus. My problem now is the brakes are TOO cool, as the Hawk pads need some heat in them to work really well. The Focus has as much rotor and a bit less pad then the Aerostar does, yet the Focus weighs nearly half as much!

If slotted or drilled rotors can take away some of that heat(which we know causes fade and warping ) build-up from stopping a van with too-small front brakes, then it's a good thing. After these rotors are done, I might just try drilled or slotted rotors.