Further to my previous posts I have now removed the calipers for further inspection. What I found was a bit of a mess! The topic of pad lift (or shim lift) has been precisely discussed but nothing has been never been documented. I couldn't find any detailed images of exactly what this disease entailed or how to correct it. I have taken photos of the old shims as fitted to the calipers and what I found underneath;
I noticed a small amount of lift and a bow in the centre if the shims;
Removing the shims revealed the issue;
This one shows just how bad the build up got
One of the calipers had to be split as I sheared once if the torx bolts off when trying to remove. A local engineering shop drilled it out and fitted a helicoil.
Once the **** was all cleaned off new plates and stainless Allan head bolts were thread locked back in place;
The calipers are now ready to fit back to the car along with new discs, it may be that the new yellow stuff pads (that were filled to fit the swollen shims) are scrap. They will be fitted to the car to see but I fear too much metal has been removed.
I expect a large number of early cars will have this issue, the shim is of a very poor design and the drain points behind the shim don't allow water to drain correctly and as a result brake dust builds and corrodes the aluminium.
Any hoo, this is now nearly complete and I expect the same on the rear!!