Originally Posted By: SteveSRT8
here's the real deal on rotors 'warping':
http://www.stoptech.com/tech_info/wp_warped_brakedisk.shtml
Written by Carroll Smith!
And how do we mate 'old' pads to new rotors?
http://www.zeckhausen.com/bedding_in_brakes.htm
Just dress out those old pads with some 150 grit sandpaper and put them all together as per above. They'll be mated just fine.
Note that not every pad maker puts an abrasive layer on for break in. That's only on EBC and a few others.
A bit of work, but an easy way to tell if the rotors are indeed warped or if they have uneven deposits of pad material on them that cases the judder---
---Remove the rotors and sandpaper the surfaces. We don't want to remove metal, just clean the surfaces. Wipe with brake kleen and re-install. If the braking is smooth for a while, then the judder returns, you know that your pads are not adequate for the heat developed in your braking style. Buy better pads. If the judder is still there with clean rotors, buy better rotors.
Also, a stuck slider on the caliper that prevents the sliding side of the caliper to move smoothly with the rotor runout will cause the braking vehicle to jump around. There is always runout...there are no perfect rotors nor perfect mounting surfaces. Depending on the vehicle, allowable runout can be as little as 15 ten-thousanths of an inch or as much as 3 thousanths.