decided to take the wheel spacers off and let the wheel center itself. Tightened the calipers and still have the same issue. Soft lever and loaded rotors.

This is crazy!!!

all the pistons seem equal, the pads seem to be square to the rotor yet the rotor flexes. when you loosen the caliper exactly a 1/4 turn all is good. While doing that nothing seems to move at all.

 

Do all of the caliper pistons move freely? If 3 out of 4 o
are moving but one is stuck, or even binds a little, it might be loading the caliper/disk unevenly like the stuck moving caliper you described above. Just grasping at straws because having the same problem on both calipers seems unlikely. Are they new or used calipers? There might be an accumulation of dust not thoroughly cleaned off of one piston causing this. Since loosening the bolts slightly relieves the bind, I would suspect the problem is on the inner side of both calipers. Have you tried installing the calipers without the brake pads just to see if something doesn't line up?

 

They are CVO take offs. They look virtually new. I am going to take them right down to see if something is not right. Grasping at straws too.....seemed like a simple install. lol

 

Still looking at this and not really making any progress. With the calipers off and the pads removed I can watch the pistons move. They all move eventually a different rates. When one encounters resistance the other starts to move. Seems normal to me. So when mounted they all appear to be touching the pads. Yet when applying the brake you can see the rotor flex. Which, would give the indication that a piston is seized. Then backing off the bolts to the caliper allows everything to work perfect. Don't get it.....yet lol

 

Try backing off the bolts and then tighten them one at a time and see if you can isolate which bolt is causing the issue.This may point you in the direction of what else could be the cause. Maybe one of the bolts on each side is causing the caliber to.get tweaked?

 

You've probably already done this, but the rotors can be a stickler if they're not installed per the service manual. Just grasping at straws.

SugsPa

 

What brake lines are you using?

 

I have tightened these things every which way possible. As far as the rotors they are true and have minimal runout. Brake lines are magnum sterling chromite. Chrome banjo fittings. Had to drill hose end out for the fittings to fit. Hydraulic side of things has to be good.....when the calipers are loosened a bit they work perfectly fine. Crazy stuff!!

 

The rotor will flex on both sides at the bottom. I measured the right side flex at .004 to .005 to the left at the lower outboard caliper piston. The top inboard piston flexes the rotor to the right. This movement is what's causing the soft lever. In order for the rotor to flex the piston and pad must not be applying force on the opposing side of the movement. Yet you can feel the opposing pad move. The piston that's flexing the rotor has to have good pressure behind it and that pressure should be the same that is acting on the opposing piston causing it to apply equal force. If it was seized it would not move......wish it was that easy lol

Shoot this all to heck cuz when it's loosened it's fine. Something in the alignment of the caliper is changing when it is tightened. I think. But even if was slightly misaligned the pistons should accommodate this. All though the pads would be angled to the rotor for uneven pad wear etc. statically though the pads should all male contact and apply equal pressure and the lever would feel fine. Driving it would be another story.

Sorry if I am rambling and not making sense at this point. Talking out loud and hopefully I will have that glory moment.....lol. You know how it is when you have looked at something long enough you go kinda crazy...lol

 

you say the handle is spongy..is it possible that there is air in one side of the wheel cylinder and not the other so that one side is pushing harder than the other side???maybe try fill the wheel cylinders with the brake line unhooked with a syringe or something before you bleed the brakes