2004----Like many others, I increased the length of the master cylinder pushrod because of the soft long throw of the pedal I have done this successfully on 2 other Fords with the same problem. Doing this gave a PERFECT pedal. Yesterday driving for a mile or so, I started to feel the brakes dragging without touching the brakes. By the time I got home I could smell the burning pads.

I shortened the pushrod and everything was fine just a little more pedal throw. Today same deal, after about a mile they start dragging again, but not as bad. I let the truck sit a couple of hours and the brakes were back to normal. What is going on?

 

stuck caliper would be my guess...

 

Suspect caliper as well. Sounds like your piston is expanding when it heats up causing it to stick. Their phenolic and will absorb moisture over time causing them to expand a bit. The wheel giving off excessive heat or has a bit more brake dust is likely the one giving you problems.

You could also have an internally failing brake hose. They can sometimes act like check valves and not allow a caliper to retract as it should.

 

Not sure if it's connected to the issue but have you used your parking break recently? I had mine seize and "ride" on the rotor creating the same smell you describe. Check the above posts first as I'm sure the answer is there, but if not, this is an easy check...Good luck!

 

E brake cables are not connected.

Third test drive (no changes) same deal. At first I have normal brakes, no dragging at all. After 5-10 minutes I start to feel gradual dragging and the longer I drive the worse it gets. It appears to be affecting all 4 wheels (no pulling).

Did I exasperate an existing problem by extending the rod, or is it coincidence that a new issue came up at the same time I decide to work on the brakes?

 

Maybe you need to shorten it a little more?

 

I had sticking intermittent brakes on front oem Units . It was after a brake job I tried everything until I heard it was common problem with the pistons absorbing moisture and sticking after being pushed back in . Both left and right fronts acted up . The only fix was reman calipers.
That was over 100k mi ago and another brake job . Mine was a rwd so it ruined my front bearings ,baked the grease right out of them . So I went with the centric mod that allows me to use 4wd rotors on front ,no more removing expensive throw away nut and tightening to 295 foot pounds . .

 

Tomorrows project is to shorten the rod even more to see what happens.

 

I am familiar with internal brake hose failure but it is happening to all 4 wheels.

 

I wonder if your issue may be in the master cylinder or abs module then.