Rotors warping 3rd time in 7 months.

[Kirch]

Brought my 2021 Mach e in to get its rotors looked at for the 3rd time in 7 months.
bought car used in June 2023 decided to get the brakes looked at before it went out of warranty in January. They trying to machine the rotors but were to bad so paid for new ones. Fast forward 2 weeks and the rotors were warped and the replaced them again in February. Fastford to end of March and they were warped again. The claim it’s the bad brake pads and ford sent new ones because old were defective. They machined the rotors that were out on in February and put new brake pads on. Fast forward to this week 22jul24, they say it’s user error and they are warping because I slowed down to fast using my brakes. I use one pedal drive and probably just a few times a month I brake hard coming off a highway. At this point it feels like ford is gaslighting me. Anyone Ford techs have any advice??

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[McSquashy]

I'm no mechanic, but did they check the hubs for built-up corrosion or make sure the caliper slide pins / pistons aren't gunked up and sticking?

Seems to me that there's a missing piece to this puzzle.

 

[Kirch]

Their master tech said he didn’t see anything and when they asked a ford engineer the engineer said it’s user error and you showing brake hard from higher speeds and the rotors shouldn’t go bad that fast. I’m like I know they shouldn’t so just at a loss right now.

 

[McSquashy]

I'd get a second opinion from a reputable 3rd party mechanic. Best of luck!

 

[TheSteelRider]

Your rotors are wiggity, wiggity, wiggity wack. You need to see a doctor. I can refer you to mine on the west coast, Dr. Dre.

 

[HGxxx]

Brought my 2021 Mach e in to get its rotors looked at for the 3rd time in 7 months.
bought car used in June 2023 decided to get the brakes looked at before it went out of warranty in January. They trying to machine the rotors but were to bad so paid for new ones. Fast forward 2 weeks and the rotors were wrapped and the replaced them again in February. Fastford to end of March and they were wrapped again. The claim it’s the bad brake pads and ford sent new ones because old were defective. They machined the rotors that were out on in February and put new brake pads on. Fast forward to this week 22jul24, they say it’s user error and they are wrapping because I slowed down to fast using my brakes. I use one pedal drive and probably just a few times a month I brake hard coming off a highway. At this point it feels like ford is gaslighting me. Anyone Ford techs have any advice??

I am sorry but " slow down too fast using brakes" what are they smoking? That's what brakes are supposed to do.

 

[AZMMESTAR]

"...Wrapping..."?

Do you mean "Warping"?

 

[Snakebitten]

I'm not convinced that the rotors are warping. It's a term used for a lot of rotor anomalies that technically is not a warp.

Anyways, I love the braking on this car almost as much as the acceleration. It's amazing they can Haul this slab of battery down the way they do. If aggressive braking is a user error, I'm erroring pretty consistently. No one warping.

 

[Space_Pony]

"...Wrapping..."?

Do you mean "Warping"?

I thought he was talking about a birthday present.

 

[bigredx86]

Since we’re asking this everywhere, here’s my post from FB.


As soon as they replace them rotors go out for a test drive, push and hold traction control off, make sure you hold until it disables control track, you will notice the difference. This will turn off blended braking and only give you brakes with no regen and no one pedal. Get to a spot and do as many 60 to 20 mph panic stops till you smell the brakes, then drive for a long time, few miles never using the brakes.

This is called bedding and heat cycling the rotors.

Then when you’re on your way home from work, normal commute, and you do fast deceleration, when you come to a stop, give yourself space, every so often coast forward.

I can’t stress this enough, never extremely heat your rotors and sit at a light, this will warp them after multiple cycles but if you heat cycle them, like I stated above, it will help avoid this.

If they feel warped right after they put new rotors on, take it back, they didn’t clean behind the rotors well.

 

[Fixbear]

Their master tech said he didn’t see anything and when they asked a ford engineer the engineer said it’s user error and you showing brake hard from higher speeds and the rotors shouldn’t go bad that fast. I’m like I know they shouldn’t so just at a loss right now.

Location and weather does have an effect on rotors. They use friction to create heat as the form of energy to stop the car. Heavier the vehicle, more heat. Now when the rotors get hot and then get wet, they cool in the wet area faster than the rest. So they have to make them with cast iron to try and prevent warping. Problem with iron is that it rust fast and easily. Especially in salt environments. When stopped in wet environment's you will get light rusting in areas not under the pads. This is just surface rust, unless it sets for extended periods. With daily use it just brushes off. Setting for a week, it gets deeper. To the point one can feel it in the pedal.
And if you use one pedal, they shouldn't even get warm. Unless the calipers are bad and not retracting the pressure on the pads. Or your driving style requires a lot of traction control. Also the rear has electric motors to set the parking brake.
Now, their are all levels of rotors out there. And price can be double of cheaper ones. If you pull a wheel and look at the hub, there will be a casting mark in the face if it's OEM. OEM's are a alloy casting that have a little better corrosion resistance than the aftermarket brands.
Normally when caliper problems occur, it's one wheel. And the tech will know it. Providing he's observant. But normally do both as pads come in pairs. Unfortunately, in some shops they do not encourage communication between the tech and service writer/service manager.

 

[zvez]

I am sorry but " slow down too fast using brakes" what are they smoking? That's what brakes are supposed to do.

yeah, it's kind of hard to have a warm and fuzzy feeling about that service dept, if that's what they're telling a customer is the cause.

 

[zvez]

Location and weather does have an effect on rotors. They use friction to create heat as the form of energy to stop the car. Heavier the vehicle, more heat. Now when the rotors get hot and then get wet, they cool in the wet area faster than the rest. So they have to make them with cast iron to try and prevent warping. Problem with iron is that it rust fast and easily. Especially in salt environments. When stopped in wet environment's you will get light rusting in areas not under the pads. This is just surface rust, unless it sets for extended periods. With daily use it just brushes off. Setting for a week, it gets deeper. To the point one can feel it in the pedal.
And if you use one pedal, they shouldn't even get warm. Unless the calipers are bad and not retracting the pressure on the pads. Or your driving style requires a lot of traction control. Also the rear has electric motors to set the parking brake.
Now, their are all levels of rotors out there. And price can be double of cheaper ones. If you pull a wheel and look at the hub, there will be a casting mark in the face if it's OEM. OEM's are a alloy casting that have a little better corrosion resistance than the aftermarket brands.
Normally when caliper problems occur, it's one wheel. And the tech will know it. Providing he's observant. But normally do both as pads come in pairs. Unfortunately, in some shops they do not encourage communication between the tech and service writer/service manager.

I'm inclined to think something wrong with that particular car's brakes. This is not normal.

 

[CopperRobot]

My rotors were warped upon delivery new. Took multiple visits to service department before a manager drove with me so I could prove to them they were indeed warped.

They turned the rotors under warranty. This was a year ago ore more. They warped again and I haven't bothered with getting it fixed. I have an appointment to get them fixed this week, but at 52k miles it will cost me this time.

I don't know what's causing the warp to return. I don't drive crazy and brake pretty gently most of the time.

Maybe I should ask for new pads while it's in?

 

[azerik]

1. The factory rotors suck
2. The factory pads suck
3. Replacing with factory rotors without bedding them properly will lead to warping.
4. The pads rust to the rotors, (this feels like warped rotors but isn't, they'll turn them, you'll lose metal and it'll do it again next time it rains) which is why I replaced mine with https://www.powerstop.com/product/power-stop-z26-street-warrior-brake-pads/ However I still get, with brand new pads, and brand new rotors, the feeling of warped rotors in the steering wheel. I'm convinced it's a CV (or half shaft) again and not the rotors/pads. I can feel it more when I'm on the go pedal and when turning and accelerating. It comes and goes with different temps, tire pressures, number of passengers, alignment of the stars and moon, new IOS releases, national holidays etc.
I've spent a LOT of time and a LOT of money chasing this vibration.

FYI The rotors arn't warped per se, pad material is sticking to them, then the pads smooth over the rusted together pad material/rotor and it will NOT come off. The attempted re-bedding might help some, the occasional 60 ->0 stopping in N so it's only using the pads might help, but it's going to be back. I'm hoping the Element 3 Coated rotors and power stop pads don't rust together. It was a shot in the dark on an otherwise one way street with the factory crap.

Here is the TSB about it:
https://www.macheforum.com/site/thr...rakes-brake-pad-material-stuck-to-rotor.8971/

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