I have a 94 Bronco and my problem started when I replaced the anti-rattle clips for the driver side front disc brakes. I bought a set of aftermarket anti-rattle clips and noticed that the steel was a little thicker than the original. I ended up replacing both sets of disc brake pads and noticed that I had a hard time installing the new pads with the new anti-rattle clips. The new pads were very tight and really didn't move freely at all. Either the new clips were too thick or the brakes had too much paint in the grooves where the anti-rattle clip sits. I normally use Raybestos pads, but Pep Boys stop selling them. So I went to Advanced Auto Parts and I think they sold me Bendix pads. So I figured Bendix was a decent brand and installed them. Now, I can smell the brakes heating up when I use the brakes alot. I have removed the pads and ground down the grooves on the pads, where the anti-rattle clips sit. I also bought a set of Ford anti-rattle clips, but these didn't help the problem. The pads move a little more freely, but I guess it's not free enough. My question is, how much play should the pads have once they're mounted in the anti-rattle clips?? Should I grind out more of the grooves??

 

I would try bleeding the calipers real good. The fluid may be dirty enough so the calipers do not release all the way. Just my two pennies.