Baked Brake???

[Pops944]

I just started getting a profound smell of what I believe is a brake overheating. After driving about 10 miles on the interstates I get a familiar smell that seems to be located at the driver's front brake. I've had the pistons in the brakes on motorcycles bind up not allowing them to release, which in turn heats up the rotors (in some cases to the point of glowing red). The smell I get in the car is almost identical to that smell. I can also see more brake dust on that particular wheel than on the others. I'm wondering if the caliper could be the problem or the rotor. Any suggestions on the route to take. My gut says rebuild the caliper, and replace the pads. Also, considering replacing the rotors. They don't look chewed up, but are definitely worn. Any suggestions before I dive in?

[mikepellegrini]

After driving, if the wheel is noticably hotter than the other wheels (to the touch) then yeah, that's a sign the caliper's hanging up.

And they can get really hot - I had an 87 Taurus wagon and one front brake hung up and got so hot it completely melted a plastic hubcap before it locked up. It was sizzlin' hot when we stopped. Literally.

I believe they sell rebuild kits. I'm not sure what you do - I believe basically you just hone the cylinder and piston, and put in new O-rings.

Another good idea is to completely change the brake fluid after you're done (you'll have to bleed it, anyway, so what the hey...).

[Pops944]

Gotta love stupid easy problems. Drove the car to work this morning to check caliper heat level (only 4 miles). At worked checked calipers; driver front too hot to touch, other three cool to the touch. Brought car home, pulled caliper off and removed pads. While removing the pads I found a piece of gravel wedged between the pad and the caliper. Each time the brake pedal was depressed the gravel worked down a little lower. After removing the culprit, I broke the glaze off the pads, re-assembled, and everything works well. The rotors are at the replacement level for wear, so I'll probably get new rotors, pads and brake lines. Replace it all and flush/bleed the system. Now the question is ...... what are the odds?