Brembo Caliper Piston Corrosion

[skeletonizer]

2006 300c SRT8

I recieved my EBC Yellow Stuff pads yesterday and thought it would be a nice hour project to change them today before I went into work.

Not so much! :SM002:

I started on the right front and noticed that the dust boots did not go back into the caliper like they should. I got to poking around and noticed that thier appeared to be plating coming off the pistons and a lot off corrosion.

Here is what I found:



This is not the worst one, it is typical of the four. I have not torn into the other corners yet but I assume they will be the same... at least on the front.

I am posting this up prior to researching options on getting this fixed. If anyone has suggestions I would appreciate it. Please don't tell me to take it to the dealer as that is not an option.

I am hoping that I can get pistons, seals and dust boots for a reasonable amount from somewhere.

I will also flush the system as some of the plating or corrosion may have contaminated it.

Has anyone else experienced this and what was the outcome?

[skeletonizer]

I just changed out the rears. They showed none of the corrosion or flaking of plating. The pistons are of the cup disign not solid. Not sure if they are oven of the same material.

[skeletonizer]

Just got off the phone with sales at Zeckhausen. No go on the pistons there.

[skeletonizer]

Just got off the phone with sales at Zeckhausen. No go on the pistons there.

They put me in touch with Brake Warehouse. They have reconned front calipers for $150 each. Pistons and seals come to damn near that.

They are going to call me back as soon as they check to see if they have the silver ones.


Both DZ and Brake Warehouse are super cool and easy to deal with.

[EricG]

Tony,
Well that's certainly concerning. I'm having new pads put on Wednesday of next week and will try to get a look at things. YOWSA! Be sure to share that with the SRT Engineers.

Eric

[skeletonizer]

Originally Posted by EricG

Tony,
Well that's certainly concerning. I'm having new pads put on Wednesday of next week and will try to get a look at things. YOWSA! Be sure to share that with the SRT Engineers.

Eric

I'm going to put together a post for the next chat session.

[skeletonizer]

I have unpainted brembos coming for $120 each.

So...

When I go to paint these things where do I find a brembo stencil or decals? I want them to appear stock.

[topfuel67]

How many miles do you have? Would this be covered under the 36,000 mile? I know pads aren't, but calipers should. I'm at about 34,000 and am going to check mine out this weekend!

[skeletonizer]

Originally Posted by topfuel67

How many miles do you have? Would this be covered under the 36,000 mile? I know pads aren't, but calipers should. I'm at about 34,000 and am going to check mine out this weekend!

36,500

No longer interested in taking my car to a Chrysler stealership.

[skeletonizer]

The purpose of this post is to consolidate all the pics and text into one coherent narrative to post in the next SRT chat session. This issue has potential to be widespread in the not too distant future. It could be a warranty issue for someone who has not washed their hands of the Chrysler service network. Please provide feedback and suggestions and I will edit the post as needed. Thanks for the help in advance.

Everything below the line will be cut and pasted to the next SRT chat session.
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Let me start by thanking you guys for an awesome machine! It is worth every penny. It has operated nearly flawlessly as a daily driver rain, snow, and shine.

Early in July I attempted to change the brake pads on my 2006 (build date 03/06) Chrysler SRT8. The pad change was initiated due to the fact that the rear pads were nearing the "squeeler" pad wear indicator. They still stopped the car like always but it was time for a swap.

Upon removing the right front pads I noted the plating had come off the face of the caliper pistons. (pic below taken much later after calipers were removed)


The car is a year round daily driver in Northern Michigan and has approximately 36,000 miles on it. The pads are original and the rotors were replaced per TSB# 05-006-06. The below pics shows the wear on the front pads at the time of the discovery.


It was noted that the pistons on the inboard side of the caliper would not return to the bottomed out position. The dust boots were rolled back and it was noted that the plating on the pistons had been compromised all the way down to the pressure seal. One of the pistons was removed for further inspection. (pictured below: The top pic is of the piston upon removal, the bottom is after brushing the loose plating away to show the extent of the plating failure.)



The plating on the outboard pistons did not appear to be as bad. The driver side showed signs of the plating on the face failing (see pic below) but it did not fall off during dis-assembly. Uneven resistance was noted on the inboard pistons of the driver side when placing them into the bottomed out position.


The dealer had no caliper parts available other than dust boots. They were more than willing to sell me calipers to the tune of $400 each. I have since fixed the problem for considerably less than the cost of just one new caliper.

On a side note the rear pads showed a bevel or taper to the wear. (see pic below)


What is the purpose of the shim on the rear pad and it's unusual shape? (pic below) Would not the fact that the piston is bisected by the edge of the square holes cause binding of the piston in the bores? Just curious?


No doubt you are impressed with my brevity.

Have you noted other failures of this nature?
Is the caliper still an "unserviceable" part as the 2006 Service manual indicates?
Are their plans to offer caliper parts in the future?
Have materials or design changes to the SRT8 calipers been made since the production cycle began?
If another experienced this problem and was willing to let a dealer tech work on the car would it be a warranty item?
Would custom stainless steel pistons work in the caliper without other alterations? (I know, but I have to try. )