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I have the same problem with my '02 GT 5 speed. It started when it was driven to Indiana during the bad storm last year, Jan. 2005. I have changed all 4 calipers, all 4 rotors, front / rear pads, new hubs in front. It has had a abs system check on machine, complete brake system fluid replacement, tires balanced rotated 3 times, front end alignment, rear diff fluid change w/additive, trans fluid checked.

I have heard just about everything from brakes, bad calipers, alignment, hubs dry. I had the exact same problem with a Pontiac Firebird. I finally changed the struts to fix the problem. I have attempted to get the struts changed by 3 different shops, which is covered under my extended warranty. Everyone says they check good. Bounce check/visual check. I think the problem is in the struts, or possibly dry ball joints. But, no mechanic will change the latter 2 for me, so for now I am stuck with a noise/brake grinding feel that is driving me nuts and has lasted a year. It will be there, until I change them out myself. Best of Luck...

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MustangMafia

changing the struts fixed the problem on the pontiac? or the mustang?

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I had a Pontiac Firebird with abot 42k miles on it, when the same problem you are having occured. I did full brakes, tires, balance, rotate, with no fix. The struts were finally changed out by a local mechanic, and it fixed the grinding feel/brake noise.

As far as my '02 GT, I have tried everything but swapping struts and ball joints. three separate dealers and one Master Mechanic (specializes in Stangs) say the struts aren't bad. So, I haven't had luck with getting them changed out. When I get some down time from work, I will swap the struts out myself. I currently have 45k miles on my GT.

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MustangMafia

I had my mechanic drive my car and he said the problem was my ABS system. He said that I just had to live with it because he couldnt change it unless Ford had a recall on it.

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Did he put it on the ABS test machine, or just tell you that, because he couldn't figure it out. I had my ABS sytem checked by computer. The pressure test checked good. It cost $135, but it was piece of mind. I changed all four calipers, and had a complete brake system flush and check. Mine was all good.

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One other thing, does it make a humming noise from about 15 - 35/40 mph? If so, I have the same problem you do.

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Pull the ABS fuse #29, to check if it is ABS or not. I tried this last night, and the grinding did not go away. I may look at the ball joints this week.think I

domesticlover

my bet is that your one of your calipers is frozen. you need to replace the entire caliper.