manny - I remember seeing the caliper and wondered why it had the cutaway. Are the marks you mentioned on the caliper?

mpolli - Thanks, that's a great idea. I'll try it next opportunity.

Hatterasguy - You might be right, I've heard that same thing about tires (I work in the Akron area and know lots of tire experts). If I replace the rotors, I'll go to the dealer this time.

Sounds like I have plenty to try next weekend. I think I'll do the free stuff first (measure temp, check piston orientation, etc). Thanks everyone for the help, I'll let you know how it works out.

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2008 ML350
2007 Honda Element
2007 Honda Accord
2009 Honda Civic