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Your math is great, but just because the springs have 3 lbs of force doesn't mean the pads are pushing that hard on the rotors. It may only take .5 lbs to push the pads back and the extra 2.5 lbs is only creating more room after the initial clearance is made. It only takes a few thousandths of movement in the pads to get them off the rotors. Let us know what the results are.
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1991 F-250:
4.9L, Mazda 5 speed, 4.10 10.25" rear
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