Looks like a good project. I would be concerned about what you described about the brakes. It could be alot of different things causing that issue.
Owner reviews for brake pads
Raybestos Element 3. They last a while and bite pretty well when braking hard
I've used Power Stop Z17 and Z23 on many many vehicles with no issues. No noise, low dust, excellent bite.
Pads and tyres affect braking the most, the actual discs themselves matter much less. Just get some higher tier metallic brake pads and you should be good. I would go for Brembo Extra pads personally.
Bendix Ceramic. $20. OG rotors at 140k, they've been turned once and are within spec. Next time I'll grab the DD Centric rotor/pad combo off RockAuto for $55.
Hawk HPS 5.0 pads, Raybestos AT. I'm on my 4th? set of front pads+rotors after 125k miles. Rears are still the stock.
I run Akebono brake pads, they're great!
There is a lot of markup on those parts. A full set of TRW pads for an S60 can be had for a little over $200 inc GST from Repco and Repco ain't cheap.
i went with Raybestos Element, after reading they performed OK, and the price is fairly inexpensive. so far OK with minor issues. during installation, i shaved a hair off the pad material and the pad ears to get them to fit not as tightly. and after installation, the pad sometimes makes a click sound when changing direction of travel, or sudden acceleration after a complete stop. i think the pad is moving around in its mount and making a sound. did some searching and this might even happen with OEM to some people. i added more grease to the pad backing, noise went away for a few weeks, but later returned.
I ordered Bosch brake pads after installing them. I noticed a knocking sound and if you look in the pic there’s a gap at the top and bottom of the ears on the pad. I threw my old pads away so I couldn’t even compare them. Only when driving really slow then braking or in reverse. Didn’t do it every time but the noise is driving me crazy. I also installed new rotors front and back and it’s only the front driver side making that noise.
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