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Your EXP is much heavier than the F150 it's based on. Take that into account, and if you're driving with a full load and/or towing, all the faster the brakes will wear. Are you offroading with it getting abrasive into the brakes? To me, a 1998 is too young to have major problems with sticking calipers in normal driving, but you might want to consider checking them out. Both the pistons and the sliding mechanisms. If your front brake hoses have deteriorated or have damage, they can cause the disc brakes to drag. Remote chance the master cylinder is plugged where the fluid pressure bleeds off when pedal is released. God Bless, jd
I have one E-350 shuttle bus that goes through front brake pads every 10K miles and a new rotor and caliper every 30K.
I have another E-350 shuttle bus that is virtually indentical in weight and use that has yet to need front brakes with almost 100K miles.
The difference is the one has a driveline retarder and the other one doesn't.
The basic problem as I see it is the brakes are too small for the application.
I also do not think the rear brakes are doing as much braking as they should be doing. If the rear brakes were doing as much as I think they should be doing the rear linings would be wearing out at a similar pace. Our rear linings are replaced once for every 5-7 sets of front pads.
If you are driving in a lot of stop and go situations, or if you are towing any large loads, or if you drive on any significant grades your brake usage is going to eat up front pads.
We have tried various different types of pad material as well. With some materials we have seen reduced pad wear with increased rotor wear. With other materials we have seen significantly greater wear of the pads with little to no wear on the rotors.
Unless you invest in some sort of auxillary braking system I don't see your brake pad wear changing significantly regardless of what you do.
Just to add; if the front brakes are sticking (caliper piston or caliper sliders) the inboard brake pads wear significantly faster than the outboard pads.
Something to keep in mind: The pads that you can buy for your vehicle from the dealership are made with a heavy-duty semi-metallic compound that wears a lot slower than what you can buy from your local Checker's. I'm a big fan of saving money, but you'll find that you'll buy fewer brake pads overall if you buy them from a Ford dealer. 20k to 30k miles is normal wear for front brakes.
Just for your information, I am shop foreman for a county road department. All of our 1998-2000 F150 pickups have this same problem. I have tryed all sorts of pad and rotor combinations and nothing seems to help. I believe this to be a design flaw that Ford will not admit they have. It started right from the first set of factory pads and is an on-going thing. If you find a cure let me know.
I am working with an automobile industry as a testing and development engineer. Interested to know more about lining wear pattern and best way to calculate the projected life.