I searched this but no luck finding an answer.
I recently did a disk brake rotor and pad replacement on a friends car. One of the pads would not fit in the allocated space in the caliper frame. The mounting hardware was seated properly (removed the rust that had formed), there was nothing else in the way, but the pad was just too long for the space in the caliper mounting frame. So, I ground off what was probably one thousandth of an inch, maybe two thousanths, bottom line, very, very little material came off. Just enough to take a tiny bit off, try the fit, repeat till it seated in the frame.
Couple of questions:
- Is this the correct procedure when this happens?
- If it is, should I have painted the now bare metal "ear" to prevent it from rusting? (I did use a high temperature silicone lubricant to keep it moving against the new stainless mounting hardware)
- Is there anything else I should have done to the ground down "ear" to insure a long serivce life?
Note: The car was a 2004 Kia Optima, with 160k miles. Since the replacement the brakes are much improved. They are a floating caliper design, and the caliper guide pins were cleaned and lubricated.