I think a good part of the bad braking performance with the Edge is the coefficient of friction (cf) of the brake pads Ford is using. My 04 Sienna had WAAAAAY better brakes than my new '08 Edge Limited. I don't think the pads in the edge have enough initial bite, and I find braking smoothly very difficult in this truck. I suspect that a pad with a higher cf at a lower temp will do wonders and allow one to modulate the braking better resulting in better braking but also smoother braking. I went through a similar change on my old race car (http://www.frankenmini.com if you're interested) and pads make all the difference. Too bad there is no way to get the cf graph of the OEM pads, I'd be curious as to what it looks like. Changing the pads should also improve pedal feel.
Bigger rotors won't help, rotors are giant heat sinks for dissipating the heat, and the brakes in the Edge suck all the time, not just when the rotors are hot. Bigger rotors don't help make the car stop any sooner unless the brakes are getting too hot. I would say the Edge brakes get mildly better as they warm up, which gives my theory on pads some plausibility.
For those that aren't aware a car doesn't stop because the caliper are trying squeeze the rotor so hard that it stops the car. The secret to brakes comes from the cf of the pad, higher the cf the more stopping power, while at the same time being harder on the rotors. In my race cars (new one is http://www.brutusv8.com/ if you're interested) I can adjust brake bias (how much front vs rear braking force there is) front to rear with pads by almost 10% by just changing the pads in either the front or rear or both.
Now, all this said, if the master cylinder isn't giving enough PSI to the calipers, and/or the piston size of the caliper is too small the pads won't be able to generate the friction they need to be truly effective. Fixing that would be very expensive, and virtually impossible due to stability control and anti-lock brake system control units.
So this msg is a round about way of me asking, do any aftermarket brake pad companies make pads for the Edge?
Paul