Weird wear pattern on new rotor?

Rotor is 2-3 weeks old, new pads and new reman caliper (this is the same side with the leaky caliper from a couple weeks ago posted about here). What is causing the weird wear pattern only at the top of the rotor? It's the same on the outside and inside of the rotor. Is the pad resting on the rotor? I haven't fixed the caliper yet because the seeping stopped so it's not high on the to do list although the entire caliper is already rusty! When I replace the caliper, can I still use the rotor?!

 

What brand are the rotors? Got a pair of calipers handy? You could measure the thickness at the top of the rotor and again in the middle to check to see if its thicker at the top. Im thing its a manufacturing error in the rotor. But also make sure those pads slide freely in the caliper just to make sure they arent getting hung up. Are both rotors doing it?

As for the rusty caliper problem, I used the duplicolor ceramic caliper paint that I got from Autozone. I just masked off the pistons and gave it a few good coats. Been a year and they still look great.

 

they're Duralast (father in law works there so got a discount on them, this is my second set (warranty). First ones warped so badly in less than 6 months because the original 180k mile calipers were very sticky...)

I do have some calipers I could measure rotor thickness this weekend. I'll check that the pads and caliper slides freely. It's only the one side too. Other side looks perfect.

 

I want to replace that passenger side caliper. I don't have a pic of it but it literally is covered in rust. Even the bracket is rusted. I may paint the new one when I replace it because paint will probably last longer than whatever "coating" they use when they reman 'em.

 

As mich as I hate to be that guy, Id suggest spending a bit more for Brembo or Centric Rotors off RockAuto or Amazon. I have Brembos on my truck, no issues

 

long term goal is big brakes so i was trying to go cheap. But yes, that thought has crossed my mind more than a few times.

 

Remanu calipers are notorious for uneven cups which apply pads at slight angles. This wear pattern is excessive and indicates a severe drop in stopping power. The pay me now or pay me later principle applies here. Those calipers will ruin the rotors in short order or turn you into a bloody rear bumper decoration in a panic stopping scenario.

 

well that's not good!

 

when you put the pads in did they slide right in or did you have to hit them in.. looks like the pads stuck in the slides. its wearing crocked

 

I'm pretty sure they popped right in but I'm not 100% certain. That was at the very end of a frustrating long day!

I think it should be easy to notice when I pull that caliper off if the pad is hard to get out the slides. Thanks!

 

So the rotor measures 22 mm thickness. I measured a number of spots around the circumference of the rotor and it appeared to be uniform. Of course there could still be that one spot that happens to be just a tiny bit thicker than the rest...

The pads were actually the opposite, they were pretty loose in the slides, like they could slide forward and backwards about 1/8". That seemed like too much to me. I've never had them move that much before. Maybe the pads were constantly resting on the rotor? Also, it seemed that they didn't quite fit correctly either. There was already a little lip wearing at the top because the top of the pad was sitting above the top of the rotor. I threw on the old pads which worked great but dusted like crazy.

 

Just going by what we see in the pics, uneven pressure/contact causing the wear in the higher pressure area around the outer part of the rotor. What could cause that?

You say the rings are the same both sides, and all the way around, so warped rotor doesn't seem like the cause. And you have confirmed uniform thickness, so incorrect machining seems ruled out.

If the pistons in the caliber were applying pressure that unequally, they would likely be sticking/stuck. I've had that happen on old, worn, dirty calipers that had been in the mud too many times without cleaning. The piston comes out at a bit of an angle and they stick there

If the calipers were loose for whatever reason maybe they are moving a bit when the pressure is applied and the force is being shifted to the outer area of the pad.
If the faces of the pads were uneven/not flat, that might cause it. They should be gradually wear flat. Not advocating you keep them, just saying if you removed them again in two weeks you might notice gradually the wear ring getting broader and broader as the pads wear flat.

 

@ireymon take a picture of your caliper and pads while mounted. from your description you either have pads moving or the wrong rotors (pads should be centered in the braking surface)

 

Take a pic of your pad, you have a pad moving or an improper install as you should not have wear all the way out to the outer edge of the rotor.

Can't remember if yours ride on the pins or in the channel but either way I expect that pad is hanging up and not mating correctly with the surface of the rotor. I use super lube to grease those parts and make sure your pins are not corroded, if they are that will cause this issue.

 

I'll have a to get a pic this weekend, you can't really see it through the wheels. I know the rotors aren't wrong because of the way that the 5 lug rotors mount to the back of the hub.

5 lugs have the pads with the little tabs that slide into the caliper bracket. Maybe both pads were messed up or maybe the caliper was cockeyed when i put them on but the fact that both inside and outside are wearing the same is bizarre. I'm going to get a warranty rotor and caliper this weekend so that should hopefully fix it.

 

do you know for sure the rotor/hubs are identical left and right? they should be me thinks (not side-dependent) and the pads should be mirror images of each other.

unless something is stuck behind the pad(s) it's very odd to have that contact patch. also, even if loose in the caliper make sure there is no rust/flaking metal behind where the pads sit, this could cause uneven surface.

 

You are correct, pads and rotors are identical for both sides.

I can't help but think that the caliper was just messed up from the very beginning. It leaked (I think the rust stopped the leaking!), it completely rusted in less than 2 weeks and I feel like maybe a defective caliper is what is causing the weird wear pattern.

Gonna be replaced soon so that'll be the end of that!