Technical front callipers and pad cage - brake judder

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Technical front callipers and pad cage - brake judder

multihull

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Aug 4, 2009
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Sunbury on Thames
I seem to have different sized callipers and pad cages on the front of my Stilo JTD MW (115) 04 reg.

Braking from speed had a severe judder at the front, if pedal depressed very very hard it seemed to stop. Diagnosis - disc distortion/pad breaking/caliper sticking.

The story is below but I need to find out where I can get, at reasonable cost, the correct brake pad cage. I can p/ex the calliper and get a correct one for the model.


This is what I have been through, lucky that I have been able to drive it for some 2000 miles and really enjoy it - looking forward to a tour in it through France later this year.

First off with wheels, alloy locking bolts would not come out. Down to friendly garage which released 3 with their air tool and my key, front offside key kept slipping off. To my not so local Fiat garage who checked their key set which was different size to mine but identical design, mine were Fiat I think. Looking at it they said the bolt was burred. Anyway needed wheel off so drilled out locking bolt, more later if anyone needs info.

The nearside disc appeared clean and came off easily as did the pads.
The offside disc was a mess with big pitted rust marks on the outer face, pad had obviously not been making good contact. With effort got the calliper freed and the pads were tight fit, needed a hammer blow to release. They could have hardly moved in cage, which had 3 of the insert sliders.
Replaced both discs and fitted pads to nearside ok. The pads would not fit in the pad cage with the inserts in and moved. Calliper checked for movement OK.

As car on axle stands started engine and applied brakes, nearside braked well, offside jittery. Maybe needed bleeding, 8mm small spanner on bleed nipple and the top came off of the nipple. Tried to drill/easyout the nipple unsuccessfully. Now my problem is will the correct calliper fit the incorrect cage?? Or can I get matching calliper and cage?

Stilos being farly rare is there an alternative manufacturer using Bosch ZOH callipers with 54mm Piston and 52 sq cm padsthat anyone knows of.

After all of this any assistance is appreciated.
 
John - Thank you. I will try them next time as i seem to resolved this.

The offside pad cage was holding the pads so tight that I needed a hammer to release the outside one and the outside of the disc was lightly used and had deep rust pits.
Replaced discs, pads and slider bits, easing the offside pads in with a bit of grinding down so that they slide in the same as nearside (dodgy cage). Broke the bleed valve trying to remove it so replaced calliper.

On test all working now with no judder.
 
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