My car has been exhibiting the following in my front passenger side brake...

- depress brake pedal when driving... feel rattle through peddle until fully depressed. Suspected warped rotors. Replaced with brembo rotors and new pads on both sides in front. Fixed for a bit. Came back on passenger side.
- Replaced caliper clips. Fixed for a bit. Came back on passenger side.

- I assume its the caliper assembly at this point... I hate to replace that and not fix the problem. My audi guy says he's never seen a caliper go bad.
- I was also thinking brake lines??

Thoughts? Similar experience?

 

Try pulling the slider pins out (the ones that anchor the caliper to the carrier), clean them completely, clean out the bores that they thread into, grease the hell out of them, and reinstall them. The plastic caps that cover them can degrade and allow moisture in. They can corrode and bind up. Cleaning them up will eliminate that as a cause at the least and should ensure that they bite and release smoothly.

 

Napa will have replacement hardware kits, Pins/bolts/boots, whatever. Grab one of those, replace all your old stuff. Take a drill bit, as exact to the size of the bore in your caliper and run it through a bit. Don't eat up the hole, just clean it. Use synthetic brake grease in the pins, so they don't swell the rubbers. Also use a bit of sandpaper or similar and clean the hat surfaces on the rotor (inside and out) and the hub assembly, rust can build up in there, heat + pressure from the lugs can warp your rotors easily.

IF something is causing your caliper to drag, warping the rotor, you'll need to cut or replace your rotor.

Also, make sure the Pads move freely and easily within the bracket. If not, replace the abutment shims and clean rust off the bracket. Don't be afraid to modify the pads as well, I have to grind the paint off of quite a few pads (the edges, where it rides in the bracket), some manufacturers just slob it on there. Also, grease where the caliper contacts the pads, front and back.

There you go, perfect brake job.