I drove my Disco down to LA last weekend and half way down the brakes started making some awful noises. I didn't have any tools down in LA so I hurried home to take a look at what was going on. To my surprise I found this-



First observation when I pulled the wheel off was that the inside brake pad was sitting down at the bottom of the disk brake shield. Thought, "That's not good" Pulled the caliper off to reveal that the pistons had been riding the rotor, I fished the remainder of the pad out and that's what it looked like.

I did find that one of the caliper bolt pins in the caliper bracket had frozen due to rust. I'm guessing that left enough room for the pad to wiggle out and fall into the shield. From there on it wore itself out on the rotor as did the caliper pistons.

I've reset the calipers for now, they seem to be working ok despite the damage. I've ordered new rotors and pads in the time being...

 

oh and another question... what size socket is the star bolt that holds the caliper bracket? I'm going to have to order a new one, and I don't have that socket in my tool chest.

 

Your brake pad worn so thin it fell out of place and your caliper was pressing onto the rotor, which chewed it up because its not meant to do that.

I think it is a 12point 1/2" socket.

 

The other side had 70% material remaining on the pad, I leaning more towards rust related on the caliper bracket pin which should slide freely in the caliper bracket.

 

I think it is a 12MM 12point socket.
Shop Kobalt 3/8" Drive 12mm Shallow 12-Point Metric Socket at Lowes.com

 

Thats harsh man.

Check out RockAuto Auto Parts for good deals on calipers. Also eBay has good deals and factory ones.

 

A stuck caliper could make that happen.

 

So you now need a set of rotors, calipers and brake pads and a good 2 quart DOT 4 brake flush have any scource for them, if not shout.

 

I've ordered most of the parts from AutohausAZ already, they're in the one day UPS Ground shipping zone and have some pretty good prices and free shipping to boot. I'm going to keep the calipers, They're functioning even with the damage.

 

Are you planning on rebuilding the calipers and installing new pistons, that is a must.
Who's pads did you order, don't want to throw on some cheap ones and get the 3 amigos.