Noise started out as a small squeaking. I was thinking it was pre-mature brake pad wear, at 29,000 miles, and the noise was just the metal low brake pad indicator. It began at the start of a long trip I was taking to another state. About 70 miles in, the noise grew to be a continuous grinding and squealing noise, when going <40-50 mph. When I arrived at my halfway point I got out of the car and inspected the area. Not seeing anything major, other than some really shiny rotors, I knew it was brake-related but not catastrophic. In my book catastrophic would have meant "get it to a service center now!" and I would have been staring at a broken rim, smoking brake pads / caliper, or a brake rotor cracked in half and seized / not moving. Thankfully it was none of these, so I completed my business at the half-way point and proceeded home.

Due to work, and needing my vehicle for daily travel, I postponed the repairs by a week. The noise continued to sound at the above-mentioned intervals, and it did not seem as though the vehicle was having issues with moving because of it. No loss of power or dragging on performance. All seemed well, except for the sounds. I finally took the vehicle in and they diagnosed the issue to be exactly what I had thought it was. The right-side rear caliper was stuck in place.

My local Ford service center replaced the following parts: Disc Brake Pad Set (P/N: FR3Z-2200-K), Brake Rotor Assembly (P/N: GR3Z-2C026-E), Disc Brake Caliper (P/N: FR3Z-2552-J), Passenger Side Brake Flex Hose Assembly (P/N: FR3Z-2282-C) and lastly, Rear Hose Brake Washer (P/N: -W711784-S300). When they changed the rotor and the caliper they recommended that I do a brake system flush, to purge the system of any water or moisture, which could have rusted out components if left un-done. So I did that as well. So far there seems to be no issues with the repairs, although I only drove it the 8-12 miles home from the service center.

I understand "s*** happens" and bad parts get made, but the vehicle only has less than 30,000 miles on it. These brake components shouldn't be wearing out that fast... Usually even the cheap brake components can go for 50,000 - 100,000 miles, from what I am told. They informed me that if they were to have machined down the current rotors, they would have been at the minimum marks, and more prone to warping. So, all 4 rotors and all pads got replaced, and the vehicle got a full brake system flush. Sad to see this on a car that was "Built Ford Tough". Tough as what? A pack of kittens?