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I watched some videos and I am convinced the rust on hub surface could cause this. Even though I spent 1hr cleaning hub surface with wire brush on a drill, I did start to chip the dirt off by a screw driver following a video on utube. They do come off even do wire brush couldn’t. I ordered hub surface cleaner that sits around studs that should arrive tomorrow morning. I feel I can save the hubs. Also, I am going to drill the sliding pin rubbers with a 13mm drill bit to make it bigger. I am not sure if it works. The idea is to have pins free when calliper gets hot.
The sliding pin alteration will be interesting. Would it be worth only do one thing at a time so that you can be 100% sure what fixes it?

As a side note, the more I read this thread the more insane all this time and effort seems.
 
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MY 2012 XF S Portfolio Ultimate Black
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Discussion Starter · #222 ·
The sliding pin alteration will be interesting. Would it be worth only do one thing at a time so that you can be 100% sure what fixes it?

As a side note, the more I read this thread the more insane all this time and effort seems.
I only found 14mm wood bit today. I think it would be fine because it’s rubber. Maybe It cannot cut at all.

yes I really cannot spent more time on it. I have taken apart brakes 3-4times in past few months.

I have seen another strange thing on old rear discs. There is a deep lip on the edges. About 1mm each side. The contact surface though measures 19.5mm. There was a lot room left. However, the thickness over the lips is 22mm. The rear discs come in 20mm and min is about 17.5 to 18mm. It seems lips are inflated for about 1mm. This was large enough to grind the pad sensors. However I didn’t have pad warnings. Is the assumption right that discs can inflate due to rust? Or old disc was somehow thicker than standard?
 

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Yes, rust on the lip will certainly increase the diameter. It will have been the correct size when you got it. If they're oversized slightly when new and you've got new pads too, they probably wouldn't wind back far enough to get them in.

Pretty sure from my college days that it can increase the size by up to 7 times its original size in extreme circumstances. That's why rebar in concrete can crack the concrete if it's allowed to rust.

Easy solution to it is to jack the back of the car up, let it coast in first gear with the wheels off and run round the lip with a grinder and flap disc on to get the worst off. It may need the T/C turning off to allow it to run properly.

Front wheels...bit more awkward but doable. That said I've never had an issue with oversized lips causing any binding :oops:
 

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Discussion Starter · #224 ·
Yes, rust on the lip will certainly increase the diameter. It will have been the correct size when you got it. If they're oversized slightly when new and you've got new pads too, they probably wouldn't wind back far enough to get them in.

Pretty sure from my college days that it can increase the size by up to 7 times its original size in extreme circumstances. That's why rebar in concrete can crack the concrete if it's allowed to rust.

Easy solution to it is to jack the back of the car up, let it coast in first gear with the wheels off and run round the lip with a grinder and flap disc on to get the worst off. It may need the T/C turning off to allow it to run properly.

Front wheels...bit more awkward but doable. That said I've never had an issue with oversized lips causing any binding :oops:
Thank You. I am replacing the discs anyway. Winded back the piston all the way and there is 5mm room with the new disc and 3mm with rusted one. I think a similar thing is happening to hub surface that I hope to be able to grind off. Kit hasn’t arrived yet. Amazon prime one day delivery used to be impressive!
 
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