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Ok I have a 2000 Exp with 90K miles on it. I have been having a problem with the front rotors warping on me. I have turned them twice in the last two years and now they need to be replaced(can not be turned anymore to thin). It is not driven hard or in the mountains(except for one week a year). What can be going wrong with the rotors? Could one of the calipers be sticking? If so how can I check this and then fix it? Also what rotors should I go with? I am tired of replacing the brakes on this thing, although I am getting much faster at it. Thanks for the help.
Common problem.
Turning them reduces mass, making them more prone to warpage.
I used to run cross-drilled rotors, but pad life was crappy.
I'm on Brembo plain rotors now. Only like $70 each. So far so good. I think any plain or slotted rotor from a reputable aftermarket MFR would be good. I'd stay away from the Ford OEM rotors, IMHO.
Had the same problem with warped rotors. Turned them twice, each time they warped again within 10K. Replaced them with new rotors 50k ago and have not had any problems.
I replaced mine 2 years ago with standard aftermarket rotors i picked up at NAPA or Kraigen (can't remember where).
I've had no problems with them since. You said your Expy isn't driven "hard", but how much stop-and-go driving do you do? My wife goes through brakepads on our Expy pretty fast because she does tons of stop-and-go driving. As long as you replace the pads as soon as they give signs they are going out you shouldn't have to mess with the rotors at all.
I also purchased my pads at a NAPA/Kraigen type place and they were lifetime pads so i just return them and get new sets whenever they are on their way out at no charge. Waiting too long to replace your pads causes chaos on the rotors. (metal on metal is never a good thing).