I have a 2000 i30. The front brakes are intermittently sticking to the point of smoking brakes.

Both rotors, pads and calipers have been replaced.

1. Right front brake started sticking a few months ago.
2. Replaced caliper, pads and rotor on right front.
3. Does it again.
4. Gets cherry hot 2 times.
5. ABS, Slip, and TCS lights come one.
6. Find out wheel sensor mounting screw broke and sensor fell out.
7. Wheel sensor replaced. Both calipers, pads and rotors replaced up front.
8. On way home from shop, now LEFT front starts smelling and smoking. WTF?
9. Next day, riding fine early on, then both sides are dragging and causing smoking and heat.

BTW the lights went off when the wheel sensor was replaced and have not come back on.

Could this be a master cylinder issue, plugged lines, or booster check valve??? I'm at a loss.

What can I do short of torching the car ......

 

Have you tried to spin the wheel(s) by hand to see if there is drag on them?

The caliper slide pins corrode and the brakes cannot release properly. Check them.

It is possible that the ABS controller is confused. It is interesting that a wheel sensor came off and you didn't get a check engine light. Either remove the fuse for the ABS unit or disconnect the battery cable for about 5 minutes to reset it.

 

Turns out it was the right front brake hose. Degraded to the point that it was acting like a check valve. Mechanic says when people use a c clamp to pinch lines this will happen down the road. All is good now.