This is my Nightmare!
 

Hi folks,

Picked up my 03S from winter storage. Noticed significant rust on the rotors so I drove back and forth on a quiet road to try and clear it up a bit. The pedal and response all felt great after a few stops. Prior to storage I had the external brake lines replaced with steel ones, fluid replaced, connection block and hoses all replaced.

On my drive home, roughly 30 miles of highway, the "brake wear" light comes on. While exiting the highway the pedal goes to the floor........ "AHHHHHHHH! IM GUNNA DIE!!!" - is my only thought. Felt lucky to not have any traffic or any sudden need to stop. Was able to slow down enough to shift into first to limp the final (excruciatingly long) few miles home.

The first thing I noticed was the strong burning smell. Next, my rear rotors looked red?

Any ideas on how I can avoid ********************ting my pants next April? Thank you!

http://986forum.com/forums/uploads02...1618929526.jpg

Looks like the rust just isn't worn off completely, maybe the Caliper is a little stuck accounting for the smell, most likely there is air in the lines..Fluid level good ?

Your rear pads seized onto the rotors. Further, likely the brake pistons seized a bit. Have you inspected the pads? Have you removed the calipers to inspect the pistons and seals?

Next season leave off the emergency brake then at the beginning of the new season jack up the rear a bit and hand spin/rotate the rear wheels to ensure they're not stuck.

Replacing the seals isn't extraordinarily complex... and rebuild kits aren't terribly expensive.

That's what I'd do.

Good luck!! :cheers:

NEVER store any car with the emergency brake applied!.....nuff said.

On 986s the hand brake does not use the disk rotors... there are little drum brakes in the hubs. They can still seize up, of course, but that would not explain a problem with the rotors or the pedal going to the floor. Also if you were able to drive around normally I doubt that the hand brake was the problem... although it could have been making contact and heated up and seized.

Ebrake didn't cause the above. Issue was the caliper seized and then most likely blew a seal on the piston which is why the pedal went to the floor. OP never reported back so we dont know what/if anything was done to fix it.

Maybe during a second "test drive" he wasn't able to stop?.......RIP

(seriously, a follow up reply from the OP would be appreciated)

I wonder if you overheated the brakes.

The glowing red would be an indicator of that