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I replaced the rotor and pads on my 2000 expedition but now i am having a problem replacing the 2 t45 bolt through the caliper into the caliper bracket. i can get the top one in ok but the holes on the bottom are not lining up. the caliper is riding about 1/8 of an inch too high to line up. anyone run into this problem?
i would take the caliper back off and measure the hole center line to center line and compare to the old caliper. Maybe they sold you the wrong one? Maybe it was made wrong? Maybe the bolt is cross threaded and not straight, i hope not.
Well seeing how you only replaced the rotor and pads....the existing caliper and caliper mount are still the same. So the only things that may be the problems....
1) Anti Rattle clips not fully seated
2) The rubber boots for your slide pins have a attached washer with 2 flats sides for indexing(keeps the boots from spinning?) my guess is the flat side isnt where it should be? If the flat side isnt where it should be the second pin wouldnt fit in the hole.