Brake problems, new rotor gouged and ABS light on

Hi,

One of two things are most likely the cause. First, do this. Lift that wheel off the ground and have someone press the brakes until that wheel locks. Next, have the helper release the brake. If it doesn't release, open the bleeder on the brake caliper and see if then releases. If it does, replace the rubber brake hose to the caliper. If it doesn't, remove the brakes and the brake hardware. When the brake pads mount in the caliper mounts, check for rust. What happens is rust will develop under the brake hardware and cause the hardware to lock the brake pad into one position and stick. If the pads don't move easily in the mount, chances are that is the problem.

I attached a pic. I circled the hardware I'm referring to and highlighted the caliper mount that can rust. I always take a small file and clean those areas completely before installing the hardware.

By the way, if the caliper releases when you open the bleeder, then the mounts aren't the issue. Instead, the hose has most likely broken down inside preventing the brake fluid from returning to the master cylinder.

Do this and let me know what you find.

Joe

Before condemning the ABS module I would replace the brake hose for that side. What can happen is that the interior of the line can fail and act like a check valve. That causes the line to hold just enough pressure on the caliper that it cannot retract the pads away from the rotor. In effect it is riding the brakes the entire time. Very common failure, especially on and old line, or if someone used a line tool to clamp the line while changing a caliper.