2nd Gen Non-Engine/Transmission Front Calipers , new aftermarket, what's out there

[BK]

So, here I go again, another hung up piston in another front caliper.
I get about 1-2years or so, and one of them starts to hang up and drag, or all together hangs up.

99 2500 4x4 (8800lbs)

I do front pads every year... tons of stop and go.
I felt it last fall when compressing the right one, it was tough to press in, should have replaced it than.

I flush / bleed my brake system completely each year with fresh fluid.
I've done it on the truck since new.
I have a vacuum power bleeder, makes it real easy.

Seems once I replaced the OEM calipers, these Autozone and Napa (no more napa stores by me, so nothing but autozone left) calipers are crap.
I went for the best life time calipers from Autozone.. but still no better than the cheapo's...
And yea, they'll replace the bad on, but not the good one, and who wants to do brakes 2x a year, or replace calipers each year, insane.

Does anybody know if someone is making some NEW and of far better quality calipers?

 

[Cummins12V98]

Contact EGR brakes. Theirs are expensive but quality.

 

[GCroyle]

Q. assuming the caliper is cast iron, right? What is the piston made of? Have you ever taken an old caliper apart, see anything?

 

[RCapehart]

I am also to the point that my calipers need replaced. I put EGR on in 2002. Had to replace them in 2005. Stayed with EGR. I lube the pins every year. They are now not compressing right and need replaced. They are 9yrs old. Trying to decide whether to stick with EGR or not. EGR's set will run $240 with core +shipping 2 ways. NAPA's set is about $72 for the set with core and lifetime. EGR's are not lifetime.

 

[VolsFan]

I don't believe there is any improvement out there for the pre two piston caliper brake dodges. I dealt w the same stuff on my 99. Not what you want to hear I'm sure you have a lot invested in your 99 but the 4 wheel disc two piston caliper brakes on the 01 is worlds away from my old 99. About the best I could do for that old girl wads slotted rotors and hawk pads, napa calipers and still not great, only other option is swapping the axle or doing the ford hub setup which will give you two piston calipers which I still have parts for I was going to do on the 99 before I sold it. If you want to keep your ride and want better brakes I would investigate into the ford hub conversion that way you have lock outs and beefier calipers

 

[CharlieFoxtrot]

Consider A1-Cardone rebuilt calipers, available at Rockauto.com. They have been around forever and have a good reputation. I've had them on my truck for a year or two and am happy. I worked at Autozone a few years ago and would never use their brake hydraulics. Way too many got returned by customers.

good luck
kevin

 

[BK]

Q. assuming the caliper is cast iron, right? What is the piston made of? Have you ever taken an old caliper apart, see anything?

at first, but not recently... back when I did, there was just the typical rust. Now, it's broke = throw it out and replace.... so haven't cared to take 'em apart... just core returns at that point.

I am also to the point that my calipers need replaced. I put EGR on in 2002. Had to replace them in 2005. Stayed with EGR. I lube the pins every year. They are now not compressing right and need replaced. They are 9yrs old. Trying to decide whether to stick with EGR or not. EGR's set will run $240 with core +shipping 2 ways. NAPA's set is about $72 for the set with core and lifetime. EGR's are not lifetime.

Not bad at 3 years, better than I'm getting now... I think I got 5 out of my OEM set.
I do the same every year, new pads, new pins, new rubber, clean and grease, back together , bleed, beddding process.. and drive till it starts making right or left turns when braking in about 8months - 1 year... than start at the top... new pads, new pins, new rubber, clean , great, back together, bleed, bedding, till it starts making turns on it's own when braking, repeat.
Getting tired of it.. last time I ignored it for too long, I had a rotor...

I don't believe there is any improvement out there for the pre two piston caliper brake dodges. I dealt w the same stuff on my 99. Not what you want to hear I'm sure you have a lot invested in your 99 but the 4 wheel disc two piston caliper brakes on the 01 is worlds away from my old 99. About the best I could do for that old girl wads slotted rotors and hawk pads, napa calipers and still not great, only other option is swapping the axle or doing the ford hub setup which will give you two piston calipers which I still have parts for I was going to do on the 99 before I sold it. If you want to keep your ride and want better brakes I would investigate into the ford hub conversion that way you have lock outs and beefier calipers

I sort of figured, but didn't know for sure, if there was a upgrade without + sizing. BUT more so was really looking for OEM size with much better build quality than the crap I've been getting for 30bux a caliper.

Contact EGR brakes. Theirs are expensive but quality.

Thank,s as you and RCapehart mentioned above, I'll give them a call.
Before this post, I set my self to be set for a ~ 300 bux bill for the pads and calipers.

Consider A1-Cardone rebuilt calipers, available at Rockauto.com. They have been around forever and have a good reputation. I've had them on my truck for a year or two and am happy. I worked at Autozone a few years ago and would never use their brake hydraulics. Way too many got returned by customers.

good luck
kevin

Tnx Kevin, I'll take a look and do some googling about them. I love Rockauto, use them all the time... I stock up on the brake hardware from them too.
It's insane the stock at the local autozone, I can never get a complete set of hardware locally, have to run to 3 different autozones to get 1 complete set of hardware/parts to do 1 brake job.
yea, I'm done with Autozone for parts, not even getting my oil there anymore, most of my oil is not scheduled shipped from Amazon, and just got all my antifreeze there too. the one Napa that carried the G50 is gone.

Thank Gents, very much appreciate the input.
Please, any additional inputs are greatly appreciated as well.
I don't mind doing pads and hardware every year, just hate doing calipers every year, and a threat of killing the rotors.

 

[BK]

FYI, disappointed Geno's isn't carrying calipers.. they carry so much of everythings else, one would think they would.???

 

[RCapehart]

I am also to the point that my calipers need replaced. I put EGR on in 2002. Had to replace them in 2005. Stayed with EGR. I lube the pins every year. They are now not compressing right and need replaced. They are 9yrs old. Trying to decide whether to stick with EGR or not. EGR's set will run $240 with core +shipping 2 ways. NAPA's set is about $72 for the set with core and lifetime. EGR's are not lifetime.

Been reading all of the posts. We don't ,have many options to work with. My first set of EGR rotors lasted 3yrs and my 2nd set lasted 9yrs. Not to bad I guess. I may go back with the EGR again. I do lube the pins once a year.

 

[GCroyle]

FYI, disappointed Geno's isn't carrying calipers.. they carry so much of everythings else, one would think they would.???

I certainly can't speak for Geno's but I can think of one reason to shy away unless you're in it deep. BLEEDING the brakes. A caliper is sitting there waiting for pressurized DOT 3 to come charging in. Customers comments I bet, My caliper won't bleed!

OP stated calipers are breaking? Just curious, got a pic of a broken caliper?

 

[JR]

I went through the same rash of failures you did and came to the conclusion it's best to just rebuild my own. That way you know it's done right. If your doing that many brake jobs you may be better off getting a couple of rebuild kits in stock so when you have a problem you don't have to wait on parts. Or get ahold of an extra set of calipers to have on hand and swap em out then rebuild your old ones and keep em on the shelf.

 

[BK]

I certainly can't speak for Geno's but I can think of one reason to shy away unless you're in it deep. BLEEDING the brakes. A caliper is sitting there waiting for pressurized DOT 3 to come charging in. Customers comments I bet, My caliper won't bleed!

OP stated calipers are breaking? Just curious, got a pic of a broken caliper?

I'm the OP, aren't "breaking" as in physically cracking or something, piston is dragging or hanging up..
after taking apart the first one and just seeing some minor rust, after that I just replace and return for the core charge.
I gain nothing by taking the time to pop the stuck piston.

It can be felt when trying to compress the piston back into the caliper when attempting to install new pads.
Way too much effort to get the piston to go back in at some point, or wont go back in at all.....
If they did reset ok during the brake job, some time later, the old right or left turn when brake starts to show up, and the worse it gets, start feeling it in the peddle, the peddle gets mushy - than I know a piston is solidly stuck. Than the hard right or left turn (depending on the caliper) starts kicking in... like spinning the steering wheel if your not holding on.

 

[BK]

I went through the same rash of failures you did and came to the conclusion it's best to just rebuild my own. That way you know it's done right. If your doing that many brake jobs you may be better off getting a couple of rebuild kits in stock so when you have a problem you don't have to wait on parts. Or get ahold of an extra set of calipers to have on hand and swap em out then rebuild your old ones and keep em on the shelf.

I've tried that a couple of times in my life, and had bad luck with it... and just came to the conclusion for me better use of my time / quicker to throw a caliper in even if it's autozone calipers and I have to get the truck back on the road.
I generally can find the calipers, just not anything I consider quality, limited choice, and not always both sides in stock at the same store... insane... same for the hardware, so I just keep stock of the hardware from rockauto.

I just ordered the pads and fluid from Geno's, and calipers from rockauto.

I really wanted to do the EGR, but seemingly 240 for the pair + 60 core for each caliper according to one of their retail online shops ! , + the shipping both ways.

I'll give the brands from rockauto a shot first.

 

[GCroyle]

BK,

Details help. I'm NOT claiming expertise on brakes, but I do own a trailer with a total of 16 steel pistons in cast iron calipers, made by Dexter. I had piston hang up issues that overheated a rotor to about 800 deg F with temp gun.

I did the investigating via teardown and found rust in the caliper to piston area just behind the dust boots. Enough to hang them up.

I personally rebuilt 1 axle set and added a nice coating of DOT 3 compatible brake grease, yes, for internal use on break calipers and also a good amount under the dust boots. The other set was courtsey of Dexter, long story, but I did inject same grease under dust boots.

Been running fine w/o failing for 3 years. attributing failures to moisture getting behind dust boots and rusting between caliper and piston.

YMMV

Gary