New rotors are scraping caliper housing. Any fixes? - Ford Powerstroke Diesel Forum
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post #1 of 4 Old 07-13-2012, 12:42 PM Thread Starter Fanatic
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New rotors are scraping caliper housing. Problem solved, it sucks.

So it was finally time for a complete brake job, lines, rotors, calipers and pads. It all went pretty smooth that is until I drove my truck for its test run. Scraaaaape! What the hell! Everything is new and the job was performed correctly, I couldn't imagine what had happened. I went to bed at midnight exhausted from a long work week and wrenching on my truck. When I awoke the next morning I pulled everything apart and noticed that my new rotors were scraping on the inside caliper housing, the side that hold the pistons, and my anti vibration clips were trashed. WTF? Do these rotors need shims???? Can I just experiment with washers? I don't believe it's a run out issue, I just think the rotors may not be designed correctly. Should I just take the damn things back now that they are ruined or is this a correctable issue? I got everything from Napa, the rotors are rebuilt, stock and the rotors are made by Reactive One with gas grooves in the surface.

Update: I figured out the problem. My stock rotors fit just fine. The caliper part numbers are identical so it has to be a rotor size problem. It turns out the rotors I purchased fit 3/22/99 builds and later, mine was built 11/99. There is about an 1/8" difference in offset. I just ruined an expensive set of rotors by not reading everything thoroughly. Could make a nice set of expensive paper weights. Live and learn.


99 F250 CCLB Pretty much a stocker
87' BMW DINAN M6 Too many mods to list

Last edited by StoneGuy; 07-13-2012 at 01:25 PM.
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post #2 of 4 Old 07-13-2012, 07:37 PM
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Did you replace slide pins?

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post #3 of 4 Old 07-14-2012, 01:21 AM Fanatic
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Stone PM about your M6. I'm so into BMWs I have a M5
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post #4 of 4 Old 07-14-2012, 02:11 AM
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I had a similar problem with my truck. I had all the rotors replaced but one was grinding really bad when I would turn the truck. Turns out one of the front hubs had been replaced and the stock rotor was too large by like 1/16th of an inch. Not noticable by looking at it. Luckily the shop replaced it at no extra cost.

Early '99 (8/98) F-250 SD ECSB
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B&W hitch, Stancor GPR,
285/75/16 BFG All-Terrain T/A KOs,
KYB MonoMax shocks, MarinCo mod, Torque Pro
0.273M miles and counting

2002 Excursion Limited
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KYB MonoMax shocks, Fumoto valve,
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