Brake Disc Caliper problems of the 2003 Ford Ranger

Brake rotors sold by advance auto parts as an "exact fit" for this vehicle were installed without any problems and all associated components for a brake repair (pads, calipers, bearings, seals, abs rings) were also installed and seemed to fit perfectly. After assembly I noticed that the brake pads were only partially bearing on the brake rotor, with the pads overlapping the edge of the rotors. I did not notice this condition until both new front rotors had been replaced and all components except the tires/wheels had been replaced. Upon further research, the rotors sold as an "exact fit" (selected for me by the counter man at my local advance auto parts store) were approximately 1 inch smaller in diameter as the original equipment rotors. I contacted advance customer service to inform them of this problem and they denied any responsibility for installation of improper parts. Several reviews posted on the store's website indicate that other people have installed these rotors and are driving around with them despite the fact they are not the proper rotors for this 4 wheel antilock brake vehicle (they do fit Rangers with rear wheel antilock brakes). This is a murphy's law situation in which a consumer can install these parts and drive around with them, unaware of the potential for brake failure. The final installation looks normal and I would not have noticed unless I had made a close inspection and found that the brake pads were not in full contact with the rotor surface because of the smaller than specification diameter. This is a serious safety hazard because the advance auto parts website and store computer system list them as an exact fit for the vehicle when, in fact, they are not. They can be installed and driven without the installer realizing that they are the wrong size. This requires an immediate notice and recall and advance should be sanctioned.

I have had to take this vehicle into the dealership for braking problems 7 times now. There has been a constant vibration upon braking. The vibration has become so bad at times, it is difficult to hold the steering wheel. The vibration is being caused by warped rotors. The rotors have been turned and replaced at least 2 times each. I am now on my third set of rotors. The last time I brought the truck back from dealership, it was obvious the caliper was sticking. Ford even had an engineer look at the truck. The engineer looked at the truck 100 miles before the caliper was sticking. He couldn't come up with any reason for the warpage. On taking my truck back to the dealership this past time, the brake pedal started going to the floor and was making a whooshing sound upon depressing the pedal. I was afraid it wouldn't stop. I am now afraid of driving this truck because I don't know what will happen with the brakes next.