Brake Replacement Job from Hell

[AirspeedX]

Day two of replacing my pads and rotors on my 5th gen.

Have to say, super easy job - in theory. I've replaced brakes on dozens of vehicles before. I'm not a mechanic but I did grow up on a farm and have been working on my own vehicles since I started driving.

Anyways, got everything done (had a few hiccups along on the way - accidentally hitting a wheel stud out while I was hammering the rotor off and had to shorten the e-brake hold down spring pin because it stretched (??) and was rubbing against the hub) - all besides the point and all quick fixes.

Took it for a test drive and heard a rubbing / smooth grinding sound. Thought 'okay, they are semi-metallic pads in the back (I prefer ceramics) but maybe after bedding them in the sound will disappear'. Well this sound got much worse and was very on and off. Not a constant sound but very intermittent. It was either the e-brake set too hard (didn't think so because the rotor went on very easily - I did this on purpose). Or the pads were somehow too tight.

Got it home and found that a ring worn on the pad and disc. Can't figure it out. There's no way it was a rock or foreign object.

I'll post an update once I solve the issue. Contacting mechanic buddies at the moment for their insight.

FWIW - Raybestos Rotors and Wagner QuickStop Pads. Not my first choice but I had my mechanic order them in for me without specifying exactly what I was looking for. He just mentioned that he'd get me the premium products.

 

[Jhalko]

Had to get a last minute brake job right before my recent road trip. In replacing the pads the little metal clip with the new pads was not quite the same as the old and it stuck out and scraped and made noise, don't remeber details beyond that.

 

[AirspeedX]

Solution!

Had to get a last minute brake job right before my recent road trip. In replacing the pads the little metal clip with the new pads was not quite the same as the old and it stuck out and scraped and made noise, don't remeber details beyond that.

Were those the wear indicators on the front?

I checked everything and there was nothing touching - no wear marks on anything else.

I figured it out though! I ripped everything apart and cleaned and lubed all components once again. Upon re-installation I noticed the inside of my wheel was filthy. There were tiny little pebbles embedded in the layer of dirt around the wheel. I bet that one fell out and miraculously ended up between the pad and rotor.

So take note - clean the inside of the wheels often!

Similar marks were on my old rotors as well, in random areas.

Test drive #2 was uneventful. I could hear a slight contact noise but I think a few miles will take care of that. Time to bed them in properly and hopefully no issues.

I'm doing a trip to Whitehorse soon and need them to work.

 

[renau001]

Looks like you got it worked out, but noticed you said hammering rotors off. Toyota rotors should have 2 threaded holes you can screw in bolts (M8-1.25 I think) to pry it off instead of beating it off. I about drove myself crazy getting a rotor off my Highlander until I figured this out, came off super easy.

 

[Jhalko]

Were those the wear indicators on the front?

I checked everything and there was nothing touching - no wear marks on anything else.

I haven't done a brake job in 20 years so I don't remember, this was getting done literally the day before I was rolling out on a 3000 mile road trip so I had too many other things on my mind to pay attention. He showed it to me and the new versus old were different but they were not Toyota pads, probably was the indicator, the new one just had some extra metal in the wrong place and made quite a racket. Figured this will get me through and maybe I'll do it myself next time with OE pads and rotors.

 

[AirspeedX]

Looks like you got it worked out, but noticed you said hammering rotors off. Toyota rotors should have 2 threaded holes you can screw in bolts (M8-1.25 I think) to pry it off instead of beating it off. I about drove myself crazy getting a rotor off my Highlander until I figured this out, came off super easy.

I saw the holes but didn't have the time or patience to look for the right bolt. A few good whacks broke them free. I wire brushed the hub after and applied some anti seize for the next time.

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