The front brakes on my 96 Mercury Sable (156k mi) overheat on the 10 mile drive between work and home.

The heat is enough to fill the garage with smoke that pores out of the front wheel wells. The both front wheel hubs are hot to the touch.

The rotors have been warping every 10,000 miles.

I have been unable to solve the problem. I have done the following work:

1. Replaced Master cylinder
2. Replaced Front brake calipers
3. Replaced Brake Pads
4. Turned front rotors
5. Brake fluid flushed
6. ABS disabled by pulling fuses located under the hood

Mileage on the commute which is a combination of city and interstate driving is 23 mi/gal.

How do I fix this problem?

Thanks! Edited by: mike_j_wagner

 

Every time I've seen this problem it's turned out to be collapsed brake hoses. Can't see it from the outside. As they age, the interior lining starts to come apart and prevents fluid return to the M/C. That makes the calipers drag. Looks like the hoses are the only thing you haven't replaced. They're cheap.

I've also seen an out of adjustment brake light switch that prevents the brake pedal from returning to the full up position. That closes off the ports in the M/C and keeps pressure on the calipers.

 

I would have neversuspected the brakes hoses.


I was completely fooled by the outside appearance.


I took your advise and replacethe hoseson the front this afternoon.


A couple of trips to work next week will let me know if I wassuccessful.


I'll keep you posted.


Thanks and have a good holiday weekend!