So I bought my LR3 in July. By August it had developed brake judder on the front passenger wheel (this was also causing suspcross/cross-articulation faults about every 100 miles).
Brakes are brakes. I assumed that this was a pretty straightforward problem --a warped disc-- so I bought a case of beer, two new front discs and a set of pads, opened Brodsky's Brake Bible and got to work.
Front drivers side had no problems. The only problem I ran into is I forgot the brake Bible was for RH drive vehicles.
No problems on the passenger side. The disc was slightly warped (as I assumed) but there was VERY ODD wear on the inside disc and pad. In the middle of the pad there was a ridge about 2mm high and 3cm across. There was a corresponding groove in the disc. The outer pad/disc was fine.
My buddy and I surmised that the shitty dealer I bought the truck from did a 20-minute brake job in order to sell it by swapping out the pads and not replacing/turning the rotors. We swapped them out (had to use the same clips though, didn't notice they weren't included with the new pads). The judder was gone. Suspension/cross-articulation stopped showing up randomly and it handled a 3000 mile hunting the following week like the boss it is.
That was mid October. By Thanksgiving, I noticed a slight metal-on-metal whistling noise at low speeds. I have heard horror stories about the front diff's failing and prayed that wasn't it. At the Fun Zone holiday party, I loaded up the five drunkness guys I could find to help me diagnose the noise. The general consensus was a seized brake caliper/piston and not the diff (I was told to change all diff and transfer case fluids extra early to be sure).
Took the wheel and caliper off last week to find that the EXACT SAME WEAR PATTERN was already on the pad/disc in the exact same place after 4,000 miles. Look at the photos below. The first photo is the current pad; the bottom two are from October.
Mike Neal said it could be a stuck piston. One was shorter, but both compressed fine to put it back on. The boot did not appear to be damaged and I did not notice any leaks.
Where do I go from here?