Check ALL the caliper slide pins

Hot-dip galvanize everything? I'd be tempted to do that to the rear beam on our prius, except it would bugger up various connection points. That thing is inexorably rusting out, pathetic.

 

HDG sounded interesting to me too, except for a couple things: (1) if you aren't certain of the metal properties given to your part by heat treatment at the factory, the temperature of the zinc bath may change them, and (2) some parts can change shape, if their original manufacturing process left them with unrelieved metal stresses, when the temperature of the zinc bath allows it to warp. The rear beam especially, with its elaborate shape stamped and pressed into it, seems like exactly the sort of thing that might happen to (and, as a part that determines alignment, just the sort of thing you wouldn't want that to happen to).

E-coating sounds like it might be a promising approach, but the last time I looked around, I didn't find a nearby servicer to chat up for a quote.

-Chap

 

I guess the argument is that it's thick steel, but I'm sceptical, especially with critical welds, which seem to rust the worst, and sorry looking bolts. Our Hondas aged a lot better, better (and illegal now?) coatings I think.

 

The bore that the pin slides in needs to be cleaned and greased too.

Here's a tip I've used for years that works really well: Put a 1/4" bit in a hand drill. Take some steel wool, and spin the drill to let the steel wool rep itself around the drill bit until the thickness is greater than that of the caliper bore. Now use the steel wool/drill bit as a reaming tool. Once the rust is removed, remove the steel wool and wrap a small piece of rag around the drill in similar fashion for a cleaning tool. Use WD-40 to rinse. Blow out with compressed air, and you should be good to go.

 

+1 too on the rear left calipers.

...what's with the rear left calipers? and why the rears only and not the front? When I lubed mine this summer, the front pins had pristine clear looking grease on them. The rears on the other hand (specially the left) was already seized we had to heat them up to get them off.