Recently I changed out all of the rotors on my car and noticed that the front passenger caliper seemed a little more 'beat up' than the rest. Mostly just a good bit of the paint is chipped off, but I noticed something else. When changing out the rotors I checked all the pads and they looked good so I didn't change them. The problem is the rotor on the passenger side front is not wearing evenly. There's about a 1" strip in the middle of the rotor that it looks like the pad isn't making contact. I'm wondering if maybe something could be wrong with one of the pistons in the caliper or something. I really don't think it's the pads but can't be 100% sure. Anybody else had an issue like this?

 

I haven't had that problem, so I can't say much about it, but would strongly urge that you not re-use pads that have been used with a rotor with uneven wear. The pads will also be uneven and soon your new rotors will be, too.

 

Yea that's what I was afraid of. I take it pretty easy on my brakes, allowing the downshifting to do a lot of the work when coming to a stop. But, I don't want to risk a bigger problem if I can fix the root cause now. I'm beginning to wonder if a caliper rebuild kit would work. FWIW, the car has 65,000 miles.

 

After 6 years I did my brakes finally and noticed the pistons where they meet the seals were starting to rust. It's possible you might have some seizing going on there.

You can get calipers rebuilt and powdercoated fairly cheaply too. Try to find a shop locally that specializes in it.