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Does the anti-squeal backing on the brake pad appear intact? I'm sure it's hard to tell when installed.
I just replaced pads on my jeep and went for a "spirited" break-in. The paint on the back of the pads bubbled and cracked and smelled... did this on several braking events but of course stopped after 10 min.
Last gasp would be to change the fluid. Maybe there is an odd mix of water and brake fluid and the pressure or heat is causing something. <--- After reading that it seems like I am almost making things up, since it can't make sense.
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