Ahmet-

You don't mention what pads you are having this trouble with. Others, when faced with this issue, have ground down the edges of the backing plate in order to get the pad to fit into the caliper. I tend to agree that it is the build up of corrosion/schmutz behind the skid plates causing your porblem.

Best

 

Ahmet,
I had a similar problem when I rebuilt the rear brakes on my 91 S2. The old pads were really difficult to get out and then the new ones would not slide in. The problem with mine was the 2 stainless steel plates that the pads slide on. I had to take both of these out and clean all the corrosion from under then, the corrosion was lifting the plates and effectivley reducing the width of the gap that the pads slide into. This may well explain if you have warped discs as it means the pads do not pull back from the discs properly and they drag , this causes the disc to overheat and warp.
Another tip, the 4 screws that hold these plates in will be utter b**tards to get out, apparently they are loctited in at the factory so you have to warm them up to get them out. Mine were so bad I ended up taking the caliper off and taking it to work were one of our welders TIG welded a hex head screw it so I could get a better grip on it, the button head screws will round off as soon as so touch them.
Once you get these plates off you will probably see that the paint under them has come off , leaving bare the bare alloy , which will have turned into a white powder, clean all this off with a small wire brush and make sure the plates are as flat as you can get then before you put then back , use new screws and loctite. The new pads should then slide in nice and easy.
Hope this helps

Andy


<img src="graemlins/bigok.gif" border="0" alt="[thumbsup]" />

 

Ahmet mentions crackling. Soon after I bought my car, I noticed the same noise from my brakes. A rebuild cured all, although I didn't do it myself, my visa card did. They've been great since, but I bet the sound is that crud under the plates being compressed.

jp

 

Danno, here's some pictures but there's not much to see at this point:



Riff, I mentioned what type of pads I had before but you must've missed it from between the long posts, they're actually Hawk HPs (I have a set of HP blues which also didn't fit). Yeah I'm pretty sure it's all the buildup at this point.

Andy S2, I think I may go with another set of used calipers instead. I think my pistons are pretty corroded too. Doing the rears weren't so bad, but the fronts may not be worth it I guess I'll find out.

Here are a few pictures of the old (and incredibly cheap rotors):


and the new:


And in this shot you can see them side by side:

the old rotors have even less vanes in them, unbelievable, I better not catch whomever put those rotors on!

I really appreciate all the response guys!
Ahmet

 

I agree wiyh Riff. Grind them down a few thousandths. I have seen this many times before with textar, mtlmstr, pagid - it doesn't matter.Taking the steel off is a b---- and buying new calipers is masochistic.