I just replaced one of my front rotors ( I know replace them in pairs....long story) when I put the driver's side caliper back on the pads were very tight. I bumped the caliper back on with the palm of my hand, but it took quite a while and 20-30 bumps at the top and bottom. After a short test drive arround the neighborhood I noticed that the drivers side brakes had a some "smoke" coming from the brakes. It cleared up in a minute or so. I did bleed them and I am sure that some brake fluid got on the caliper. Any ideas? I am going to jack the truck back up and make sure that the brake is not locked up.

 

It could have been the brake fluid on the rotor or could have been a sticking caliper. Did you replace the pads as well?

 

Used same pads, they are only 8,000 miles old. The brakes are tight. They will turn, but only spin 15-20% of the way around.

 

Tore the brakes back down and now I am more confused. The caliper slides right off and back on. The wear on the rotor is only on the outer 5/8" of pad contact. Caliper slides on easy, but brakes are tight???

 

Sounds like your old rotors were wore at an angle which caused the pads to wear at an angle and now the new rotors are straight. The 2000 model does have the rotor that goes over the lugs, right? It doesn't press onto the hub like some of the fords does it?

 

The rotors slip right on. Can the pads or pistons calk in the caliper and not sit on the rotor square?

 

If they are in good condition they should not. What did the seal around the piston look like? I know the older Ford F150s (I have had 2), are notorious for the seal to go bad and the caliper start sticking. If the seal is bad there's a good chance the piston is sticking. With the slip on rotors they should be true. If the rotor was in bad shape and you put 8000 miles on the pads, that's enough time to make the pad conform to the rotor. Where did you buy the rotors? If you're worried about them being untrue, you can take them to a shop that turns rotors and they can tell you if they're true or not. If they only spin part of the way around and then stick it sounds like the rotor is warped or not square from the beginning.

 

I don't think the rotor is warped, when I spin the tire it is smooth all the way around. They appear to be true, but I don't have a mic to check for sure with. Using a square they are true. The seals looked intact and dry on the pistons.

 

What kind of shape was the old rotor in? Sounds to me like the pad is wore at an angle.

 

Grooved and warped. I don't know how square. If the pads aren't square, will they run in to the new rotor or warp it?

 

Well I have never seen a rotor warp from that but that harder your brakes are the more likely it would be to warp the rotor. You could pull the pads and sand them a little to get them closer to being square to help them wear square sooner. Or you could buy new pads. Before you do anything pull them off and look at them and see if the break material surface is square with the back of the pad.