I replaced the front pads on my 2003 F150 this evening. One of the caliper slide pins was completely rusted and stuck in the caliper bracket. I was able to remove it with a significant amount of effort.

I cleaned the rust off the pin with emery cloth and was able to slide it into place to re-assemble the brakes. I had difficulty installing the caliper, because the pin won't slide in all the way. I'll get a replacement pin and boot but I'm afraid it won't slide in all the way either unless I do something more to the caliper bracket.

What do I need to do to get this squared away?

-Crank

 

use one of those sanding bits that goes in a dremel tool. ive seen them for regular drills at home depot. smooth out the inside with that. use high temp grease and you should be all set.

 

Unfortunately, those bits aren't long enough to reach into the hole in the caliper frame to remove the obstruction. The pin slid in just far enough so I could install the caliper. The truck is driveable and the brakes work but this clrealy isn't right.

Any other ideas?

 

ok. well id say you could drill it out just a hair larger in diameter. would have to be done in a drill press though.cant be crooked.

 

If you use too much grease, it can create a dam which prevents the pin from bottoming out (grease, like all liquids is incompressible). Might try using a non-metallic probe to scoop out excess if that is indeed the problem.

 

Get a drill bit that's the EXACT same size as the slide pin (or a hair smaller) and use it BY HAND to clean out the bore in the caliper bracket. Rinse frequently with brake cleaner until it comes out clear. Then apply silicone grease to a new slide pin & reinstall.