1997 3rd Gen 4runner, shop's in the process of trying to make the swap for me from stock rotors/calipers to the Tundra kit here: https://www.summitracing.com/parts/PWR-KC2324-36

Both dust shields trimmed, and the front passenger side fits fine, but the driver's side has the caliber rubbing against the rotor. I'm stumped, and the shop's stumped. It's not a casting issue, as they're perfectly symmetrical when compared.

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Your shop needs to put more than one lug nut on the rotor. See how much thread is exposed on the bottom stud vs the top ones where it's rubbing because he's trying to spin it with only one lug nut on? He better give you a discount for not knowing how to secure a rotor to test for fitment...

Maybe it’s an optical illusion, but are the brake pads in the driver’s side caliper in that second photo? That would be the main thing keeping the rotor from contacting the caliper like that…

Also make sure the sticker comes off the rotor had before the wheels are installed. No need to add runout when you don't need to.

-Charlie

That was the first thing I noticed as well. I called, asked just that, was told they then tried several lugs, still had the same issue. Frankly, I think they're full of it.

Dadjgummit, I shoulda done this one myself. Just goes to show you, if you want something done right, do it yourself!

Personally I can see how more lugs might make it better, but from the pictures they look like they're riding pretty evenly as is. That is very curious though. Rotor thickness maybe?
As much as I like to flip sh*t at mechanics I would still be leaning towards a casting defect; minor differences can be very hard to spot with your eye sometimes and be pretty deceiving, and although I don't know the shop I would still have some faith they know how to do a brake job, especially if they do it for a living - I would think to them the trimming would be the hardest part of it all. Never know, I guess
Regardless I think it would still be beneficial to get it on back to your place one way or another and figure it out or else you'll probably wind up spending an arm and a leg for them to poke around and do it for you (if that's an option, I notice you're in Seattle and know that can be real hit or miss). Still a very strange problem indeed, definitely out of line from the normal TBU threads that come through

If the mechanic puts the wheel on and all 6 lugs, it will not rub on that spot on the caliper. Those calipers are remanufactured Toyota calipers. There are no casting flaws as they've already been run on a Tundra, taken off and just painted and had seals replaced. Nothing wrong with the casting at all.

And now this shop is considering making it policy to never install customer supplied parts.

I had those rotors and had the same issue. I got a set of EBC's and they installed just fine. In hindsight I would just get better rotors for the stock calipers. That being said, install all 6 lug nuts just to see if it solves the issue.

@Devbot - The shop was convinced last week it was a casting issue as well, since one side fit fine, and the other "didn't." They were so convinced, they got a replacement pair of calipers overnighted to them, which arrived today, and promptly encountered the same issue.

They basically threw their hands up today and said they tried everything (though the pic of uneven lugs makes me skeptical), and couldn't do any more.

I know they've had it in their shop a few days already, tried two different sets of calipers, and (at least i'd hope, though nobody ever went broke underestimating the intelligence of the american public) tried to secure multiple lugnuts at least once. I don't doubt that they put a lot of labor into it, but I do doubt the quality thereof.

That said, they threw on some new stock rotors and pads and called it a day. Which sucks...and as soon as I get home i'm going to try to do it myself, but it's not the end of the world.

The few other things i've done to this truck has been easy and successful. It's not a lot relatively speaking, but it is for me - airbags in rear suspension, trans cooler, some other minor items. I don't know why I chickened out on brakes, but wish I hadn't, at least before trying myself.

@T4R2014 - you said you had the same issue. Did you encounter the issue on both sides, or just one side? And agreed - this shop is probably done taking customer parts...or at least they are from me!

I also just realized how much they over trimmed the dust shields!

Have they checked runout on the hub itself?

They didn't. Everything's slapped together. But I never had any vibration while underway. Not to say it isn't runout, but i haven't at least personally witnessed any other symptoms thereof.