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Smoking badly - rear rotor failure

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Old May 29, 2025 | 09:22 PM
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From: Chester Springs, PA
Smoking badly - rear rotor failure

Good evening guys,
I am looking for some guidance. My car was running great, '93 FD. Suddenly, I started seeing smoke from my oil catch can vent filter. She still ran great. The next day I started her up and basically crop dusted the entire neighborhood. It was bad.
I drove her more and realized that even on deceleration, I was getting occasional pops in the exhaust and then when I went back on the throttle, she smoked terribly.
I then took out the leading plug and did a leak down test. I found that one face on the rear rotor was blowing into the oil fill. Like, when I heard the hiss, I put my hand over the oil fill and felt and heard pressure.
I then took the engine out and disassembled. I found a couple broken corner seals and a broken dowel (the one from the rear housing at the top by the oil filter). However, I was expecting a bad side seal. All of my side seals seem fine...at least with the engine apart. The springs are good and nothing is stuck down. At this point I am at a loss as to why the rear rotor was smoking. And to be clear guys, when I took the exhaust manifold off and rotated the engine, legit a ton of liquid oil was coming out. The rear rotor compression sound was PSH PSH psh.
does anyone have thoughts on what I should be looking for? Pics attached and can provide more.
thanks again.




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Old May 29, 2025 | 09:35 PM
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extreme_rotary's Avatar
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From: Chester Springs, PA
I should also state that prior to this failure, I was experiencing oil pressure fluxuation. I am unclear if it was /is a sensor issue, or if it was related to the broken dowel, but it would have pressure cold, and at operating temp, it would read zero at times and with no change to the throttle, it would sometimes come up off zero. I feel this related to the broken dowel but cannot confirm. Rotor bearings look good. I also tried to repair this earlier by replacing the front cover oil pressure oil ring and gasket. I did so properly while loading the needle bearing to prevent damage.
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