Brake Disc Caliper Problems of Ford Aerostar

My brakes failed after an extended downhill drive--although not an unusual circumstance. In taking apart the disk brakes, my mechanic discovered that the calipers had become brittle (over time from heat) and they crumbled in his hands. The pads had worn down but still were within an acceptable thickness (but at the low end). The rotor was normal. The mechanic believes that there is a design flaw in these brakes resulting from a rotor that is too thin (normally) and as a result does not absorb heat well from the pads. He has observed the same problem on other Aerostars and has concluded that the brakes need to be check earlier than normal pad wear would indicate. He said that we were lucky that we did not end up in an accident.

See all problems of the 1996 Ford Aerostar 🔎.

Driving about 35 mph when felt a pull to the right. The right spindl/ brake caliper andbrake line broke. Lost control of steering & the brakes. Took to the dealer. Looking at vehicle to determine cause.

Caliper failure has continually caused damage to other brake components, pads, rotors etc.

Brake caliper failure is causing damage to the pads frequently.