My 93 Exp grinds like the front brakes are metal to metal but that is not the problem. The Master Cyl, caliper, Rotor, pads, bearings are all new- Don't know what to think- maybe a cv joint?

 

If you did not have the noise before all the brake work was done then It is possible one of the dust shields behind the rotor is deformed enough to contact the rotor and produce the grinding sound. And it could be a cv joint ,but check the simple things first.

 

The noise was there before the brake work- (a mechanic had said the problem was in the brake system)- Yes the whole thing was disassembled and cleaned-

 

OK , can you tell if the grinding sound is coming from any particular area, like R/F , driver's side, engine compartment, does it change when the brakes are applied?
Please provide as much info as you can , it may help to isolate the source.

 

It sounds exactly like metal grinding in the L front wheel. I expected to see mangled bearings when I took it apart- plus there were issues that seemed like master cylinder and caliper and I thought the caliper was sticking and holding the pads closed. When I took everything apart though everything is as it should be. The noise has developed so fast I don't even want to test drive it. We didn't notice any difference when turning or braking- just a lot of noise while in motion. Even in neutral.

 

If you were to place the vehicle on jack stands and rotate that L/F wheel, you should be able to see or hear something.
If the engine is not started , and the 4 WD is engaged rocking the wheel back and forth may reveal any looseness in the CV joint.
The wheel rims ride very close to the caliper, make sure the rim isn't hitting the caliper.
Last, but not least , swap the L/F wheel with the L/R wheel and see if the noise moves to the rear.

 

I like the way you think, Hanky! I changed the wheels and the noise changed- so with the quieter situation I could hear noise in the rear wheel. I know it sounds strange- that 3 of us, including a mechanic, thought all the problem was in the front. I guess you could say I had a "hardware malfunction" in the rear wheel brakes too- mystery solved.
You're outtasite man! Thanks!

 

Boy, today is my lucky day, got two for about ten. I think I'll play the lottery !