My rotors were hardly worn, but the machining down below the pits would no doubt have made them undersize.

Junkman, I don't know what your labour rates are like down there, but I just checked and found that in 2010, PartsSource up here charged $24.95/disc.

Tw - I did have easier time on second side by skimming edge of pad backing plate a little and using a clamp to push the pistons back in.

Just started on fronts. I noticed a few things on calipers.

See the step on the piston face. It is there on both sides. Any idea why they wouldn't make piston face flat?

The rubber doesn't look great but no leakage. Any serious problem there?

The rubber that you can see is a dust boot and has nothing, directly, to do with leaking. Indirectly, a damaged boot allows grit and grime access to the piston seal, which will contribute to its demise. If those were my calipers, they would be getting some new rubber.

I agree that the calipers need a rebuild. Will see if I can find a local source. Otherwise do them myself, I guess.

ADDED: Had them done at Midland Caliper, Scarborough, Toronto. $60 each:

http://www.peachparts.com/shopforum/diesel-discussion/355589-ontario-canada-caliper-rebuild.html

Also installed new flex hoses all round and new hard brake lines from tee at back.

Bled brakes and then bedded in pads gently as recommended by TRW. Everything seems good.