This sounds like a "defect" thing!

I bought the truck at 18K and it pulled to the right.
(that help me lower the price on a private-party deal)
I still need to investigate the actual trouble (alignment/caliper/pads/etc) but it sounds like it's been identified here as bad calipers.

Anyone approach Ford with this?....

 

I didn't go to ford for mine. I figured at over 70k miles they would just give me the runaround, and I had a trip to take that I needed my truck for. I personally didn't have time to deal with the bs so I just bought one and replaced myself. Over 70k miles without one single hiccup I wasn't overly mad about having to replace one part.

 

I had a torn boot on my 07 F150 a few years ago, and the way I knew was that I got to work one day and I could smell the hot brake dust. I threw some water on the wheel and it sizzled.I'm surprised I didn't feel it hanging anymore than I did. When I pulled it, not only was the boot torn, but one of the pistons was in pieces, almost as though it had grenaded somehow.

Also, my Brother-In-Law and myself are having a "work" day in the near future on our trucks. Plugs, Coil Boots, Pads/Rotors all the way around and I watched the video above... Why in the world is there an inside/outside pad? Do the insides have the bumps (or ears as they guy described) in order to have more/better contact with the caliper pistons? That's the only thing I can think of. Poor job of Ford engineers designing a Poka-Yoke into the parts.

 

I whined about it to the service writers before I went to the parts department. One of them said "The caliper on my wife's Navigator locked up the other day on the highway. It made a pop and she thought the tire blew, turned out to be the caliper stuck and then released. It's a pretty common problem on these newer vehicles." So good luck at Ford. When the service writers know about it and have personally experienced it, I'm certain it's been reported to Ford and they don't care.

 

Sorta. The bumps on the inner pads do follow the circumference of the pistons, but they are to strengthen the backing plate so it flexes less. Unlike the inner pads, which are only being pressed upon by the pistons, the outer pads have a much larger area of contact with the caliper. Having these slightly different pad backers permits the use of larger pistons while providing clearance between the caliper and the wheel spokes.

 

Keep in mine the sliders can hang up causing pad wear or the puck inside the caliper can hang up and also be the cause of the wear.