Chrysler Repair: Hot front brake on one side, ABS:99 Concorde, chrysler concorde, lug nuts


Question
Dear Sir:
I have a 99 Chrysler Concorde, Automatic, 2.7 liter Engine, with 145,000 on it. It seems that the brakes squeal whenever you apply the brakes and even sometimes when you are just driving.
A couple of weeks ago, I was driving an the brakes smelled hot (like hot metal). The lug nuts appeared to be hot enough (to the touch) to burn you, an only on the drivers side, the passenger side was warm, but no where near as hot as on the drivers side.
The brake pedal at times would appear to be either hard or soft, an if soft it would seem that the pedal almost has to go all the way to the floor before the brakes engage. I figured that the caliber was hanging up and causing the pads to drag all the time which would explain why the drivers side was getting so hot.
The next day I did a brake job and replaced everything on the front drivers-side the router, caliber and the brake pads including bleeding the system. At first I thought things were better the hard & soft pedal is gone but now just a week or so later I can still smell hot metal and the lug nuts still appear to be hot enough to burn you after driving for any extended period of time with just normal braking.
I have brought the car to the dealer twice and both times they could not find anything wrong with the brakes. They said that the brakes are functioning like they're suppose too. The Dealer noted that they believed the Master Cylinder and the Power Booster were both functioning properly.
The brakes still squeal all the time with any type of braking action. This past week, I had the flexible brake hoses replaced on the front (both side) as a precaution, the condition appears to be no better.
Next, I had the Drivers Side Front Hub & Bearing Assembly replaced, the mechanic noted that there was quite a bit of play in the wheel and that was his recommendation so I had him do the work which also included him turning the new router on the Drivers side. The problem still exists and hasn't gotten any better do you have any suggestions or recommendations pertaining to this problem?

6-18-07
A friend suggested removing the fuse from the ABS system and see if the problem still persist. I removed the fuse for the ABS, an drove about 8 - 10 miles and the Lug Nuts appeared to be only warm, not as hot as in the past. I then re-installed the fuse and drove several more miles probably about 5 an the lug nuts were once again hot and hot enough to burn you. I then removed the fuse and drove home the lug nuts never cooled down they were still hot and only on the drivers side. Do you have any suggestions or a recommendation?

Answer
Hi Barry,
I would suspect that it has to do with a sticking valve (there are at least two depending upon which features your ABS has) inside the ABS unit that supplies fluid to the left front wheel. The tests you tried without and with the fuse showed some effect, but your temp observations were only subjective, so not conclusive. Try driving it for a few days without the ABS fuse in place and see if that ameliorates the problem. If so and you want to spend the money on it, then find an expert with the ITT Teves Mark 20 system. Otherwise, continue to drive it with the ABS disconnected as it still will stop just as if you didn't have ABS.
Thanks for the very complete and systematic history. It was very helpful. You thought of everything that I would have.
Roland