Misalignment rotor

[george-a]

I tried to fix the brakes, I have trouble in frond-left side.
The rotor seems to be more ‘inside’. The new rotor is blocked by anchor, is impossible to turn. The old one is very close, almost scratched.
Do you have an idea what is wrong? Any similar experience?


Ford Windstar 1996, 3.8L

[way2old]

Sounds to me like the parts guy sold you the wrong rotor. Tahe both of them off and lay them side by side to see if they are the same. A lot of times the parts are boxed wrong, and parts peopll pull by the number.

[george-a]

No, both rotors have perfect alignment in right side.
In left side also the old rotor is not centered, but is thin enough so is not blocked by sides.

[12Ounce]

george-a

I have bought some aftermarket rotors that were not centered ... it turn out to be a mis-machining in the area where the rotor bolts to hub. I forget exactly, but think I remember the thickness of the bolt-circle metal to be too thin.

But what you are describing seems to be a problem with the design/build of the left hand caliper itself. Have you ever replaced the caliper?

[george-a]

With the caliper out, only with the mounting bracket that holds the caliper, I can see clear there is misalignment.
I can’t believe I have problem with rotors, I have two pairs, old & new, in right side all four pieces are centered fine.
I don’t know if the problem is in this bracket.
(maybe I will try this weekend)

[12Ounce]

Check the position of the surface that the rotor mounts to ... is it possible that this piece is not fully seated in the knuckle? Is the half-shaft nut fully torqued?

[wiswind]

I have pictures of my '96 rotor / pad replacement at http://community.webshots.com/album/201931518cScpNK

I don't know if they will help with your inspection or not....but worth looking at.

During the process.....I bumped the thin metal shield that covers the back, lower side of the rotor.....and it was just barely rubbing the rotor.....was easy to bend back out.

I know that you already checked it.....but make sure that the rotor is not catching on something...preventing it from correctly seating....as in canted to one side. Same for the caliper "frame" and caliper.

[george-a]

Thank you for your answers,
wiswind, your photos are very helpful! Thank you!

As you can see from the photos, it seems that the half-shaft is shifted inside….. ABS sensor looks abused, I have abs light on.
I think something is wrong with bearing/hub assembly, which is beyond my DIY skills

[OnlyTrueThug]

Whats up people?

I have problems with my front right rotor and pads. ...First, I noticed that my brakes kept getting ate up quicker on the passengers side of the van than the drivers. I tried to replace those pads with new ones, but they wouldn't fit. It seemed that they were too wide to go on along with the rotor. So I ended up having to wait til the pads on the left side wore down enough to replace with new ones, and use the drivers side pads on the passengers side of the van. It worked for a short time! ...Eventually, it started acting up again. Something told me to just feel the backside of that rotor. It was seriously messed up. I replaced the rotor with a brand new one, and tried to put on some new brake pads, but they wouldn't fit. With the thickness of the the rotor AND the pads, I couldn't put the caliper back on, cause it would've been so tight that it wouldn't have moved. So again, I went back to switching pads side to side. I thought about having my rotor surfaced, but I don't wanna waste any money. Do yall think that surfacing my rotors would help with the fitting of the pads and rotor? Or maybe getting that caliper rebuilt? Cause it seemed that it wasn't opening up enough. ....What should I do? ...I'm so sick of all the issues with this van. -Thug

[busboy4]

Originally Posted by OnlyTrueThug

Whats up people?

I have problems with my front right rotor and pads. ...First, I noticed that my brakes kept getting ate up quicker on the passengers side of the van than the drivers. I tried to replace those pads with new ones, but they wouldn't fit. It seemed that they were too wide to go on along with the rotor. So I ended up having to wait til the pads on the left side wore down enough to replace with new ones, and use the drivers side pads on the passengers side of the van. It worked for a short time! ...Eventually, it started acting up again. Something told me to just feel the backside of that rotor. It was seriously messed up. I replaced the rotor with a brand new one, and tried to put on some new brake pads, but they wouldn't fit. With the thickness of the the rotor AND the pads, I couldn't put the caliper back on, cause it would've been so tight that it wouldn't have moved. So again, I went back to switching pads side to side. I thought about having my rotor surfaced, but I don't wanna waste any money. Do yall think that surfacing my rotors would help with the fitting of the pads and rotor? Or maybe getting that caliper rebuilt? Cause it seemed that it wasn't opening up enough. ....What should I do? ...I'm so sick of all the issues with this van. -Thug

Hi

You sound like you have done brake work before. But may I delicately ask: you do know you have to "re-seat" the caliper piston when you change the pads? I use a large C-clamp around the caliper and press against the old pad. Or you can buy a tool specifically for the process. Sorry to ask the obvious.
By the way, in my area I can walk my rotors in for resurfacing for about $10 each.

Good luck

[busboy4]

Originally Posted by george-a

Thank you for your answers,
wiswind, your photos are very helpful! Thank you!

As you can see from the photos, it seems that the half-shaft is shifted inside….. ABS sensor looks abused, I have abs light on.
I think something is wrong with bearing/hub assembly, which is beyond my DIY skills

Hi,

I don't know if you have had any vibration too? My '96 had the spindle bolt on the right half shaft come a bit loose. It chewed up the right bearing and hub and caused some noticeable vibration. I would think yours would vibrate too, however you might try putting a big deep socket (30mm) as I recall on that spindle bolt and make sure it is tight. Doing so may pull the half shaft back out into position as that is how you would install a new one.

Anyway, again I think you would have vibration and other issues but it is worth a try before you take it in.

Good luck

[OnlyTrueThug]

Originally Posted by busboy4

Hi

You sound like you have done brake work before. But may I delicately ask: you do know you have to "re-seat" the caliper piston when you change the pads? I use a large C-clamp around the caliper and press against the old pad. Or you can buy a tool specifically for the process. Sorry to ask the obvious.
By the way, in my area I can walk my rotors in for resurfacing for about $10 each.

Good luck

Thanks for answering, but thats what I always use. I force the caliper back in, and then put everything back together, but for some reason it doesn't work on my van. ...Do you have anymore ideas? Cause I'm about to give up. -Thug

[tripletdaddy]

You may need to turn it in rather than just press it in. You have this piston design only if it has a flat head with two notches on opposite sides on its top. I think rather than use the special tool, I could get away with using long needle nose pliers, llike a two pin spanner wrench. If you have the cup piston, is it going all the way flush to the caliper? If so, then you just have a tight fit with new pads and rotor. If you can't get it to go flush, than junk behind the piston is in the way and you will need a new caliper. Don't bother rebuilding it yourself, the money doesn't make sense. Does the caliper easily slide on the self centering pins/bolts? What you describe could be this, fixed by cleaning and greasing the sliding pins. Be sure to use brake grease. Is the brake reservoir open when you retract the piston, keeping the piston from going any further?