Psfred

Thanks much. The rear rotors were just above the wear limit after resurfacing, I think they were 7.4 mm and the wear limit was 7.2 if memory serves.

I never considered the rear brakes as the problem - if the rears were causing the problem that would explain why under very hard braking the shuddering pretty much disappears since most of the brake load is on the front wheels. I think I'll just replace the rear rotors and see what happens - I'd like to change one thing at a time to see if I can isolate the failure to a specific component. I'll also check the pad orientation.

The replacement pads (front and rear) were Pagids, rotors were Teves. I've heard about using sandpaper to "rough in" the rotor surfaces but I've never done it. What is the procedure? Just use 100 grit paper until the surface is roughed up a bit?

The sliding pins on the front caliper seem to be pretty lose in the bores. One of the pins has 2-3 MM of play, the others seem to be about 1 MM. Do you know how much play these pins should have? I can't seem to find any information about checking these pins in any of my service manuals.

Thanks again - Tim