Pauls2002wrx

I've had my 2002 wrx for 18 month now and in that time I've replaced the front brake discs 3 times , I'm now on a set of grooved and drilled and I'm having the same issue (warping) the passenger side disc keeps warping , I've replaced the callipers when I put the grooved discs on just to make sure it wasn't them .... I'm at a loss now , the disc itself doesn't look as shiny as the drivers side disc , I wouldn't care if I'd been ragging it everywhere but this is happening through daily driving ..... Any help appreciated ...

Cheers Paul

modrich

iTrader: (2)

What you're describing could be caused by seized pistons causing the pads to be in constant contact with the disc over heating it, but I assume you know this as you've done the right think and replaced the calipers.

Where the replacement calipers brand new or properly reconditioned ones or just second hand described as 'working perfectly' by the previous owner?

Pauls2002wrx

Callipers were fully tested re conditioned , cost me nearly £500 , I didn't think there was anything wrong with my old callipers but thought I'd eliminate that by replacing them with completely re conditioned items , I've noticed if I slam the brakes on it feels like the left hand side is still rotating when It should be trying to stop , I've got all sorts of solutions from abs sensors to abs pump and maybe new hub , completely at a loss and rather have a sign of what I should be aiming at rather than process of elimination

modrich

iTrader: (2)

Maybe the drivers side needs bleeding and all the braking force is going to the passenger side over heating it. Bleeding after fitting 4 pot calipers is notoriously difficult (I know I've done it!) and requires doing all 4 corners in a set order and repeating several times until all the air is out. Search on here for brake bleeding order.

Easy test, compare brake dust on the wheels. Also jack the front up and get someone to press he brake pedal and see if the drivers side wheel can be rotated if yes then the brakes aren't working properly on that side, then compare to other side.

Pauls2002wrx

Would that not mean it should be pulling to one side under braking ? Yes they were a pain to bleed and I think I've done them in the correct order (furthest from the master cylinder first and work closer) I'm going to strip the left hand side again next weekend to try and find anything that looks untoward

modrich

iTrader: (2)

From that statement I assume under heavy braking it's not pulling to one side?

Only other thing I can think off that could fit both scenarios is binding pistons which would suggest your 'refurbed' calipers are not 'refurbed'. Gotta say, £500 for a pair of refurbed 4pots is about £250 more than you should have paid, unless that included discs and pads. Where did you get them from?

alcazar

iTrader: (2)

We are assuming they ARE four-pots, not Brembos etc?

What you are describing sounds EXACTLY like pistons seized, one or more.

modrich

iTrader: (2)

2002 WRX, just a stab in the dark...But yes could be anything

alcazar

iTrader: (2)

LOL, he didn't say they were uprated, but then, he didn't say they were.

IF they ARE standard SUBARU branded 4-pots, my money would be firmly on seized pistons.

Pauls2002wrx

Pistons are working fine and yes they are the standard 4 pot , even with the old callipers on I went through 2 sets of discs both sets left front warped , I'd thought of seized Pistons on my old set hence buying refurbed ones with drilled and grooved discs as part of the deal , ran great for 2 month but then noticed slight judder when braking from 60 - 30 , the left front disc is slightly discoloured compared to all the rest , a symptom I noticed when the other discs started to warp ( the £500 was for all 4 corners)
Cheers Paul

Pauls2002wrx

Another set of discs replaced today , all Pistons can be pushed in with thumbs to prove they're not seized , if these warp I'm getting shot of it and going back to BMW

AS Performance

iTrader: (4)

poor quality discs and or pads could just as easily e the issue as would rear brakes being ineffective causing higher front temps

alcazar

iTrader: (2)

Out of interest, you're not one of these drivers that sit with the footbrake on, instead of using the handbrake, are you?

When the discs are hot, diffferential cooling can lead to warping, so having the brake pedal applied will keep the area under the pads hot, compared to the rest...much hotter than if the pads aren't in contact.

That can lead to warping.

Pauls2002wrx

All brakes working effectively , no pulling either way , passed mot yesterday , no handbrake is used when stationary as I'd read that siting with your foot on the brake can cause transfer of pad material on to a hot disc , ebc brakes with mintex pads , I've never had an issue with any other car I've owned , frustrated to say the least

bugeye269

I had exactly the same problem on my 2001 wrx. 3 sets of discs even after having my calipers refurbed by a specialist ( or so they claim)

I eventually bought a 2nd hand pair of calipers and fitted new seals and Pistons with another set of grooved discs and Kevlar pads from Ian at Godspeed brakes.
My brakes have never been better.
The problem on my old calipers was after the refurb that had blasted out too much where the slide pin is that holds the pads in place. Subsequently my pads were rattling around like made and making a big clunking noise once you pressed the brake. Warping the discs.

Hope this helps