[odinn7]

OK, so normally I am the one answering auto related questions rather than asking them but this one has me stuck so I want to see what kind of ideas I get here.

I was a tech for nearly 15 years and was ASE certified in brakes but haven't seen anything like this.

I have recently bought a 2003 Town and Country minivan and today the right front brake started to smell... after stopping, it started to smoke. It was not grabbing or pulling. I took it home and pulled the wheel to check everything. The caliper was not seized as the piston moves in and out freely. The caliper bolts slide easily and are not hanging up. The pads float freely on the pad carrier. I took everything apart, cleaned it all, and lubed the points of contact.

So... normally something like this is caused by a caliper hanging up and overheating but I can't find any evidence of that. I was thinking maybe the pads are garbage... anyone have any ideas?

[twinkiedooter]

Okay Odin, did you happen to drive in an area where they laid fresh asphalt? I had this same thing happen to me with my Jeep and I freaked out! I immediately called my mechanic and told him about the smell and the smoke. He asked me the same question that I am asking you - did you drive on so and so street where they had just laid some fresh asphalt. I said yes, I did, and yes they did. He had at least a dozen phone calls like mine since they repaved that road and several people even brought their cars in thinking something was wrong with the brakes.

Once the pieces of asphalt burned off the hot brakes, I had no more problems with that wheel. Then earlier this year they repaved a road I travel on and guess what? Same thing happened only on the other side of the front wheels. Smoking when I stopped and the acrid smell.

See if it's still doing this now after the actual tar has melted off. The pads are fine. Mine were fine. It basically was the tar on the rotor that made the blue white smoke and stench. That will be a $5 consultation fee payable in invisible dollars please.

[odinn7]

I don't recall hitting any newly paved roads and I saw no evidence of tar on the wheel or brakes. Also, the smell was almost certainly the smell of brake pads burning... I'm quite used to that smell really... one of those smells I'll never forget.

I suppose it is one possibility though. Thanks for trying to help.

[twinkiedooter]

Since the asphalt was not your cause my son thinks your pads are garbage after you cleaned everything. Get new pads and you'll be fine. And of course, replace whatever needs to be replaced if the part is wearing thin.

[parttime]

Odinn, sometimes the rubber brake line will break down on the inside, creating a flap that will act as check valve, not letting the fluid flow out of the caliber after release of the brakes. Good luck

[TxGreaseMonkey]

Thoughts:

. Pads contaminated by Cosmoline or brake fluid. New rotors are coated with Cosmoline to prevent rust, which needs to be cleaned off with brake cleaner prior to installation. Did the previous owner recently replace the rotors?

. Caliper pins were lubed with conventional high temperature grease, not silicone grease. The conventional grease may have bled out on the pads.

. The wheel bearing/hub assembly is shot and generating lots of heat. Check the bearing for discoloration.

. Incorrect pads were installed. Typically, this happens when semi-metallic pads are installed instead of the proper organic or ceramic pads. Semi-metallic pads are more aggressive and develop much more heat.

[odinn7]

I hadn't thought about the possibility of the flap in the brake line. I guess it could happen but the caliper released and moved very easily.

The pads did not seem to be contaminated. The hub bearing assembly might be possible though I would think I would hear something from it but there is no noise.

I have driven this van for about 1,000 miles with no problem until today. That is why I'm confused about this.

[TxGreaseMonkey]

There are many inferior aftermarket brake pads on the market today. Aftermarket pads do not have to meet federal safety standards. This is particularly a problem with some pads from China, which are not compounded to OEM specs. I stick with Wagner, Bendix, or OEM pads, shoes, and rotors.

I would also completely change the brake fluid. Old fluid lacks the proper lubricity, particularly during operation.

[odinn7]

Right... Wagner and Bendix. I have seen some pretty low-end garbage and I'm wondering if maybe that's what was put on this van. I suppose these pads could have contaminates "built in" and that may be causing the smoke. If it keeps up, I will try changing out the pads for something that I know is good and go from there.

[TxGreaseMonkey]

Check out the current promotion on Wagner ThermoQuiet Pads and see if they're suitable for your mini-van.