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First off, I'm a newb to the forum so hello everyone!
This is actually my girlfriends car and I tried to change the brakes for her. On the driver side rear when you put the new pads on the outside pad doesn't fit. Before anyone says it, I
Compressed the piston and the inside pad clears just fine, however the outside pad hits the top of the rotor. I'm told this is some sort of factory defect? I'm not really sure what to do here and she needs her car back. Thanks in advance 👍🏻
Sorry to say but you might have a seized slide pin, which in turn causes a seized caliper.
You can try and remove the slide pin and clean off the rust and put some lube on it and see if that works. But usually when the slide pin is stuck due to rust because the lube dried out, it is pretty hard to get it off. This is when you mine as well get a whole new replacement caliper.
Here is a link to a diy for the is250 rear brakes but if you read through the pages many of the forum members ran into the same problem you did. Some were able to fix it and stated what they did in the thread and some had to order new calipers or slide pins.
^Yep, exactly what I was about to say. I had to replace both of my rear calipers on my 2IS. One was 100% seized and the other about 75%. Could only barely get the new pads on the 100% seized caliper installed; and once they were, they acted as if the brake pedal was being depressed 100% of the time. Needless to say, after a new brake pad break-in, my rear pads/caliper/rotor on that wheel were almost on fire! Could have been dangerous; smoked horribly and smelled awful.