Hey guys, I need a hand with something....

I've just installed the brake evo 4 brake calipers, and it stops quite nicely. There is a problem though, there is a big clunk whenever I go over any bumps, which goes away once you start braking.

The pads I have on ATM are Bendix Ultimates, DB1223, and it looks like the pad isnt in the caliper seat properly. I have no idea at all on whats going on, as this is the pad that fits the caliper. I also dont have any brake shims for the pads, but I doubt it will make any difference at all, seeing as the shims only sit around the back of the pad, not the sides, where the caliper takes up the slack.

Ill post up photos in a second, I really just need a hand in getting my head around this.

The original caliper + pad, having no play at all
http://img293.imageshack.us/img293/2782/04052010005.jpg

DB1223 Showing play in the caliper
http://img440.imageshack.us/img440/324/04052010004.jpg

Closeup of play
http://img243.imageshack.us/img243/3176/04052010001.jpg

BIG CLEARANCE
http://img97.imageshack.us/img97/184/04052010002.jpg

Anybody help me PLEASE?!

The evo may have wear preventers over the ends of the pad tangs that take up the slack. May be part of the shims, I'm just guessing. If it is safe to do so, you can always move the pads to the position they take up when you brake, then use a wedge of metal to keep them in place, or even silastic. Don't laugh, I've seen pads with silastic on the back to glue them to the piston on one side and caliper on the other, possibly to "replace" the missing shims. Find a diagram of the evo setup with shims, and see how they work, perhaps.

Shims never come with new pads, I guess they are considered to be part of the calipers. Can you contact the source of the calipers and say "WTF is going on?"

You obviously received my front discs and hoses with banjo bolts off my TL AWD. The discs were still shiny with no rust, grooves or lips and measured 23.6mm (new 24.0mm & min 22.4mm - so not very worn at all).

Did you check your Evo 4 caliper bolts and ensure no missing spacers washers etc?

Before you fitted these you said "I'm in quite a rush to get my brake stuff together for the upgrade, as I'm running on paper thin brake pads with rotors that feel like they're buckled rims." Could this have caused or been some other problem?

When you changed the calipers, discs & hoses etc did you remove, loosen or adjust the front struts or other suspension components at all?

The answers to these questions may help informed members suggest the source and solution.

No, I lowered the car 2 weeks ago, and there was no problem at all with the car at all. And no, there are no missing spacers bolts, etc.. everything I've done has been put on very tightly. I didnt "remove, loosen or adjust the front struts or other suspension components at all"

I can actually move the brake pad around the caliper without removing the rim. Ishrub, can you please try to take a photo of a pad backing plate, maybe on your TL AWD, without taking the rims off your car, or maybe taking a photo of a spare one sitting around?
It doesnt feel right at all

http://forum.n12turbo.com/viewtopic.php?t=5522 Check this! Might not be the calipers you have ,but it shows the spacers you are missing, fit over the tangs and preload the pads. It also shows that different pads fit the same caliper.

These also came with my calipers, but there is no way to mount them to the pad OR the caliper...
http://img19.imageshack.us/img19/4351/04052010007.jpg

http://img695.imageshack.us/img695/1753/04052010006.jpg

The listed pad:

http://www.bendix.com.au/user_uploaded_files/catalogue/images/DB1223_Inner_Outer.gif

****ING HELL! Now I get it....

http://i150.photobucket.com/albums/s102/Callumgw/Brake%20Conversion/Mitsubishipartscatalogue-Brakes.jpg

These ****ing shims go on the side, not the back of the pad. mother****ering piece of shit. ****ING **** RASH!

BRB, half an hour...

deleted - duplicate of above picture. (URL to it at least)

Whoops, beat me to the pic! But you got the idea! lol You had the shims all the time!!! lol

Not very helpful post. The fit between the new pads and caliper is at fault.

Hindsight is a wonderful thing LOL. I was drafting it while the photos and your 1st reply were posted and just trying to help others diagnose and cover / rule out possibilities.

Good to see a solution has been found.

WOOT, FIXED!! Will be going for a drive now and see how it goes!!

LMFAO! Epic thread.....I can imagine you going....how the **** do these go on the back of the brake pad **** it i don't need them. lol. Nice work, least it's fixed!

OMFG, stops so hard now!!!

And you have greatly reduced the possibility that all 4 pads go flying down the road! lol

Shims are important, mmmmkay ???


Epic thread, indeed! Can someone sticky it so the rest of us can see what NOT to do? lol