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Front brake upgrade

Discussion in 'Modified 2006 - 2010 Explorers' started by Floordford, August 20, 2016.

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    1. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I have experience with changing rotor sizes a few times, and caliper piston sizes twice. The bigger rotors going from 11" 2nd gen Explorers, to the 12"(01 Sport Trac) isn't much you feel in power or brake balance. It's minor so most people won't notice it. That's what this thread is about, moving from a 12" 3rd/4th gen rotor to the Aviator 13" rotor. I rely on the other's posts for the accuracy of swapping those parts.

      The piston size is critical to brake power, and balance. I first went from 2nd gen brakes to my custom parts, over 1.5" bigger rotor, but the caliper pistons were about 1/8" larger each. That would lock the brakes at any speed, without ABS. My ABS didn't like it at 80mph. That power gain was the calipers, not the rotors. I later changed to a smaller caliper(piston size). The almost stock piston area resulted in a great balance, near normal but with still better than stock power. The bigger rotors are better, no doubt, but slight changes of caliper size(piston area) make big changes to the power and balance. I'm going to a bigger caliper again to gain pad size(volume), and I think it will require a "smaller" master cylinder. I'm planning to try a Ranger MC to slightly lower the fluid pressure with the bigger calipers.
       
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    3. Partsman109

      Partsman109 Legion of Doom Elite Explorer

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      Are you able to use an adjustable proportioning valve?
       
    4. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      You should avoid an adjustable proportioning valve if at all possible. Make that a last resort, after changing everything else to maintain the proper balances. You don't want to cut any brake line, that adds two more connections that may leak later. Race cars use them because they need to for track conditions, and any other changes they make occasionally for their usage(tires etc).
       
    5. Partsman109

      Partsman109 Legion of Doom Elite Explorer

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      I'm not sure where you learned about adjustable proportioning valves, but I think you may be a little confused.

      Why would you need to cut any lines?...if you know how to double flare it can be plumbed right under the master cylinder...
      [​IMG]

      [​IMG]
      ...or any where you want to put it, for that matter.
      [​IMG]
      [​IMG]
      You are correct as far as race cars adjusting for track conditions, but they are used mostly for big and little tire combinations and rear disc swaps, etc...and obviously front to rear brake bias.
      I don't see why it wouldn't work for our applications if you are swapping bigger front brakes.
       
      Last edited: April 24, 2017
    6. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Hey, if the PV can be plumbed close to the MC and use flared ends, that's a positive step. Those are nice example pictures of what is possible.
       
    7. Partsman109

      Partsman109 Legion of Doom Elite Explorer

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      Absolutely...some guys even use them if the one for their stock application is NLA.
       
    8. 06MountaineerPA

      06MountaineerPA New Member

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      Time to bring this from the dead for quick question. The rear spindles/knuckles for the Avaitor are...iron or aluminum? What size brakes are they, etc?
       
    9. jd4242

      jd4242 Elite Explorer

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      Fronts are 13 and rears are 12.7" and spindle/controll arms are aluminum
       
    10. boominXplorer

      boominXplorer Elite Ranger Elite Explorer

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      The rears are iron, just like the explorer
       
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    11. jd4242

      jd4242 Elite Explorer

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      You sure?? Swear when i was doing all mine they were aluminum
       
    12. boominXplorer

      boominXplorer Elite Ranger Elite Explorer

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      99% sure. I was 100% until you questioned me. I actually have a 04 aviator on my lift right now at the shop, I'll double check in the am lol.
       
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    13. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      How similar are the 3rd gen rear brakes and suspensions, to the 4th gen parts? I'm wondering about what the big changes Ford made to the chassis' were? The bodies seem very similar in dimensions.
       
    14. boominXplorer

      boominXplorer Elite Ranger Elite Explorer

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      Now that you mention it the aviator rear stuff won't swap over to 06+ trucks. 02-05 run upper and lower control arms and 06-10 run a trailing arm setup with mini links for arms.
       
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    15. 06MountaineerPA

      06MountaineerPA New Member

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      Thanks for the reply everyone.
       
    16. boominXplorer

      boominXplorer Elite Ranger Elite Explorer

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      Steel knuckle like I thought. Just posting for future reference.

      1520256514746.jpg

      1520256572536.jpg
       
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    17. jd4242

      jd4242 Elite Explorer

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    18. boominXplorer

      boominXplorer Elite Ranger Elite Explorer

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      All of the arms are steel except the upper arm, it's aluminum. All arms / brake caliper is the same between aviator and explorer / mountaineer. The only difference is the knuckles.
       
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    19. Christobal65

      Christobal65 Active Member

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      Yes I was going to say this. The way the rear suspension attaches to the knuckles is very different between the 3rd and 4th gen. I ran into it when I was doing a lot of research on what it'd take me to pull the rear knuckles to have the wheel bearings pressed out and even though almost all the videos and documents out there lump the 3rd and 4th gens together the rear suspension configuration is different.
       

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