Well, I'm completely stumped

[DSC]

Well, I got my stock, 18mm, 5lug brembo blanks finally.

I put them on last night and they work fine under normal braking pressure, and they feel normal. But under heavy(ier) braking they make a awful sound. I wish I could describe it better but its a knocking sound at first that turns to almost a grinding sound if braking pressure is held. Accompanied by this terrible sound is a burning smell and visible smoke!!

I have NO IDEA what would cause this. I took the brakes all off and didn't see anything wrong, put them back on making sure everything was just right. Everything seemed normal but it still does it <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/huh.gif" border="0" valign="absmiddle" alt=':huh:'>

Ideas:
18mm is not stock size (unlikely, sounds right to me)
The caliper wiggles just a little bit, when someone presses the brake pedal down, the caliper no longer wiggles...I'm pretty sure this is normal as well.

Help me <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/cry.gif" border="0" valign="absmiddle" alt=':cry:'> <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/cry.gif" border="0" valign="absmiddle" alt=':cry:'> <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/cry.gif" border="0" valign="absmiddle" alt=':cry:'>

[LanceS13]

If I had to guess, I'd say the torque of the turning rotor is pulling the rear-most part of the caliper into the rim of the rotor, which might explain the knock followed by the grinding. &nbsp;The buring and smoke might be caused by carbon in the brake dust igniting from excess heat from that extra friction. &nbsp;Check for signs of contact between the rotor and caliper and play in the caliper mount.
Well, that's my guess. &nbsp; <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/confused.gif" border="0" valign="absmiddle" alt='???'>

[tnord]

wow..........that's a tough one.
1st i'd call brembro to see if they put any kind of coating on there to prevent rusting and whatnot. that would explain the smoke. you know, kinda like a new exhaust smokes for a week or so because of the lube still in the pipe. also, i'd ask about how those new pads you got react to their rotors, i know it shouldn't be an issue, but with stuff like this, you just never know. but that doesn't explain the knocking.
2nd if it's not much of a hassle, put your old rotors back on and see if it still does it. if it does, then you know it's something you did wrong on the install. if it doesn't, then yeah, there's some kinda discrepency between the stock rotors and the new brembo's you just got. take measurements to see if you can figure out where the diff is.
3rd check the rear calipers to see if there's the "play" in them like there is in the front right now. or even better, find somebody else with a 240 and check theirs. if there isn't, then lance's answer might be right.

[bbp]

DSC,

Did you clean the rotors before you installed them? &nbsp;The smoke may be the crap the put on the rotors so the don't rust while in inventory.

Another thing to consider. &nbsp;The make sure the caliper is moving freely on the &nbsp;slide pins. &nbsp;Sometimes these pins can get caked up with crapand the caliper will hang up on them.

[DSC]

Alright, old rotors are back on, calipers move freely on side pins. &nbsp;Everything looks fine. &nbsp;I've successfully put front pads on my car before, and I even took my stock rotors off at the time to inspect them. &nbsp;So I guess I've done exactly this before, and it worked great. &nbsp;Now, I do the same exact thing, only putting different rotors on, and it doesn't work.

I did not clean the new rotors, I don't even know what to clean them with. &nbsp;So, yeah the smoke is probably from the coating...I say that because now, with the old rotors on, it's still having the same problem but minus the burning smell and smoke. &nbsp;

So, I know now it's not the pads being mismatched with the rotors. &nbsp;

Still the same problem though.

<img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/huh.gif" border="0" valign="absmiddle" alt=':huh:'> I'm pretty puzzled

[ca18guy]

I don't want to break bad news to ya, but i really think your pads are gone &nbsp;<img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/confused.gif" border="0" valign="absmiddle" alt='???'> &nbsp;I'm still holding out hope.

[DSC]

</span><table border="0" align="center" width="95%" cellpadding="3" cellspacing="1"><tr><td>Quote (ca18guy @ Sep. 19 2002,6 : 27)</td></tr><tr><td id="QUOTE">I don't want to break bad news to ya, but i really think your pads are gone <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/confused.gif" border="0" valign="absmiddle" alt='???'> I'm still holding out hope.</td></tr></table><span id='postcolor'>
Well, I definitely broke something. Just havn't a clue what.

Here's a shot of my pads from earlier today
http://www.steamymirror.com/dsc240sx/rotor/brake6.jpg

They look pretty normal. I'm not sure what you mean my "gone" though <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/confused.gif" border="0" valign="absmiddle" alt='???'> I'm also confused as to how different rotors could damage pads, unless the rotors coating messed them up somehow.

<img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/nervous.gif" border="0" valign="absmiddle" alt=':nervous:'> I'm gona go put the new rear pads on now, so at least I'll feel I got something good accomplished <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/thumbs-up.gif" border="0" valign="absmiddle" alt=':thumbsup:'>

I welcome any ideas or suggestions on the front.
Thanks for the help thus far guys, dono what I'd do without you <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/inlove.gif" border="0" valign="absmiddle" alt=':love:'> <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/biggrin.gif" border="0" valign="absmiddle" alt=':D'>

[ca18guy]

</span><table border="0" align="center" width="95%" cellpadding="3" cellspacing="1"><tr><td>Quote (DSC @ Sep. 21 2002,10:58)</td></tr><tr><td id="QUOTE">They look pretty normal. I'm not sure what you mean my "gone" though <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/confused.gif" border="0" valign="absmiddle" alt='???'> I'm also confused as to how different rotors could damage pads, unless the rotors coating messed them up somehow.</td></tr></table><span id='postcolor'>
gone as in wore down, time to change. &nbsp;like i said its just one of many possibilities.

[BadMoJo]

Hrmm, meh. Just throw it all out and get Z brakes. <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/wink.gif" border="0" valign="absmiddle" alt=';)'>


My guess is maybe the shims... Its been awhile since I did my brakes but I remember the shims for the pads being a pain in the ass. Check them. Then just make sure everything is tightend down... yeah, dunno. Take a few picts of the whole setup on the car. We might be able to see something out of place.

[DSC]

Here (http://www.steamymirror.com/dsc240sx/rotor) is some pics of my front brakes as of today (just brake1-6 pictures). I've now done them 3 times, still with the same problem. 2 with the new rotors, and once going back to the old rotors...problem still exists.

[camppain]

so nothing worked dsc? did you get the lines in at least? no solution? did you put anti sieze brake sieze on the caliper braket shims and sliding pins?

and btw we always tend to look for something out of the ordinary when we detect something wrong it couls be something very obvious and your looking right at it.

good luck try not to over analyze

[Yosho]

Gotta agree with James here... clean up the rotor and pads with a can or 2 of brake cleaner. &nbsp;Really use it to wash them down good.

Since this is now happening on the stock brakes as well as the new ones, we can only assume it was something that happened during or after the install. &nbsp;Do you have a second set of pads that haven't been in contact with the Brembo rotors? &nbsp;That way we can make sure sure your current pads haven't been damaged in some way.

[DSC]

Hrm, I guess I can put my old(er) pads on my old rotors, see if that does anything. &nbsp;I'm glad I saved them <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/thumbs-up.gif" border="0" valign="absmiddle" alt=':thumbsup:'>

I didn't do the lines, btw, I couldn't find a single damn wrench that would fit.

[Nismos14]

what is that first rotor? the one with the 6 lugs, where did u get that? lol

[DSC]

</span><table border="0" align="center" width="95%" cellpadding="3" cellspacing="1"><tr><td>Quote (Nismos14 @ Sep. 20 2002,2:07)</td></tr><tr><td id="QUOTE">what is that first rotor? the one with the 6 lugs, where did u get that? lol</td></tr></table><span id='postcolor'>
That first set of pics are the rotors they sent me first. &nbsp;They don't match and aren't brembo <img src="http://www.zilvia.net/f/iB_html/non-cgi/emoticons/whatsthat.gif" border="0" valign="absmiddle" alt=':whatthe:'>

[camppain]

</span><table border="0" align="center" width="95%" cellpadding="3" cellspacing="1"><tr><td>Quote (Yosho @ Sep. 21 2002,4:24)</td></tr><tr><td id="QUOTE">Gotta agree with James here... clean up the rotor and pads with a can or 2 of brake cleaner. Really use it to wash them down good.

Since this is now happening on the stock brakes as well as the new ones, we can only assume it was something that happened during or after the install. Do you have a second set of pads that haven't been in contact with the Brembo rotors? That way we can make sure sure your current pads haven't been damaged in some way.</td></tr></table><span id='postcolor'>
damn yosho were the hell have you been?!