vertically? Thats a new one on me. Almost needs to be a good worn grove to cause something like that. Can you see the spot? Can you feel the movement in your foot on the brake pedal? If no to those, I think I would take a grinder, and grind a small 45 deg chamfer on the bottom edge of both pads.
Yes, as in moving towards the upper caliper retainer and then resting back into it's normal position. There is a deep groove about 1/3rd of the way around the outer surface of the rotor -- not very thick, but a groove nonetheless. Towards the trailing end of it (wheel turning forwards) you can feel (not see) where the rotor has a high spot.
I tried lightly sanding the area which helped some but I didn't want to go too crazy on the rotor -- I didn't think to grind a chamfer on the pads though -- good tip.
As far as feeling it in the brake pedal, when driving around at low speeds when the clunking is the loudest you can definitely feel it...however once you get on the brakes it's less noticeable. When braking from higher speeds you only feel it once you get back down to lower speeds.
When I had the truck in for the alignment they noted that since they had to remove the caliper to repack the wheel bearings that they must have loosened it all up. To compensate they put some sticky stuff on the back of the inner pad which helped for a while (how that worked I don't know since it's the outer surface that's "warped", but said that if it started doing it again then they'd have to dive into it further. I'd like to avoid having to bring it in to them as I think I'm able to fix it on my own.
Another question, how tight should the outer pad be on the caliper fingers? I did have to hammer the outer pad a little as it was very loose -- it took a little force to get it on, but it's on there fairly tight now.
seen it plenty of times / the pads are chucking in the caliper bracket / the bracket is shot because of the grooves the pads wore in it / to verify it take the caliper off and move the pads vertical up and down in the same plain the rotor turns / if they chuck the brackets shot / you can try shimming them or just live with it
Yes! The pads definitely have vertical play!
Is there a shim kit available or how would you propose to shim them. It a pretty bad clunk at low speeds and I'd like to eliminate it.
Would it be worth it to get a new caliper bracket if they're still available? Could I just move the rest of the parts over to a new bracket?