I go through brakes about every 1000-3000km so I have a lot of experience with changing them.

Last few times I've switched the pads though, the pads dont fit into the new clips without grinding down the pads. If I reuse the same clips it is much easier to install the new pads in.

When I use new clips, the clips never sit flush with the caliper on the part that I circled in red. I think this is part of the reason I need to grind the pad down.



Prior to the last few pad changes the pads have slid in very easy, and would fall out on their own if not held in place. Now even after grinding, I have to smash them in with a hammer, and they do no slide easily. I have tried 3 different brands of pads on the front, and I still have the issue.

Here is the part of the pads that must be ground down in order to not have clearance issues. Even after grinding down 1mm on either side the pad still generally needs to be forced in with a hammer.


I'm thinking I've either warped my caliper mounting bracket at the track, or that I keep getting sold the wrong parts.

Anybody have any suggestions?

 

Try taking out the bracket and cleaning it with a wire brush, wheel, or small Dremel? It could have years of rust buildup that is making it not sit flush?

 

Or brake dust that's gotten packed in and pressed onto the metal that it's actually built up accumulation on that cast steel part, especially if you've gone through that many sets of pads, the dust sticks to everything. A wire brush on a drill/pneumatic tool/dremel should make short work of it but either keep it sprayed with water or wear a respirator, pretty high asbestos content in brake dust.

 

Thanks guys. I went over it with a wire brush last time but I'll try a dremel next time.

 

Can we assume you've saturated the area heavily with brake parts cleaner to at least soften it up?