Excess brake dust

[redgrandam]

I’ve been having ongoing issues with the front right brake since I got my car a few months ago. About 10,000 miles on it now.
First sign of issue was the rotors felt warped. Dealership turned the rotors and all was good for about 2 days. Then they felt warped a bit again. I booked another appointment and took it back in another few weeks and they replaced the front pads and rotors.
Now the brakes are nice and smooth, but the entire time the front eight wheel has also had excessive brake dust. This still continues.
I have booked another appointment, but now I’m into my 4th visit to the dealership over this.
They said they checked out the callipers and everything seemed fine last time. They contacted ford engineering and they are the ones that said it is probably a bad brake pad.
The dealership is being good, and not trying to push me off, but is there anything else I should get them to check out?
I suspect the next step would be caliper replacement?

Mine is a 2023 with LFP battery. When charged to full, it uses the brakes untill the battery has room to regen (or if it’s cold out). For the first few days after they replaced the pads and rotors I didn’t full charge it. I didn’t notice brake dust. I full charged it yesterday and I looked at it this morning and the front right one is again covered in dust. So it seems to be caused when brakes are used as opposed to just dragging all the time. The picture below is what the front right looks like after a day. The front left is completely clean still.

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[ron_snoop]

Did you ever find out the cause of this? The same thing has been happening to my 2023 premium for prob the past 3009km (I bought it in July of this year and didn’t notice it getting bad until sometime last month).

 

[redgrandam]

Did you ever find out the cause of this? The same thing has been happening to my 2023 premium for prob the past 3009km (I bought it in July of this year and didn’t notice it getting bad until sometime last month).

Not fully. They replaced my front right caliper. It seems better after that. But it still has more brake dust than the front left. The rotors haven’t become warped feeling again though since replacement.
I’ve found that not charging to full every night means the brakes don’t do much the next morning. If I charge to full they do more work untill I drop 5% or so. So changing that has helped a little. This isn’t a fix ofcourse. I’m undecided what to do next or if I should just live with it.

is yours an LFP model?

 

[ron_snoop]

Mine is an extended range so NCM. I usually charge to 90% every night and primarily use one pedal drive so it threw me when I started seeing the brake dust show up so often.
I just washed and waxed my car and rims last night and then drove around the city a bit today (went to about 79% so not far) and barely touched my brake pedal at all, but when I got home the right rim had brake dust all over it again.
I can deal with the dust, but if it’s a symptom of a bigger problem I’d like to address it before it causes a bigger issue.

 

[redgrandam]

Mine is an extended range so NCM. I usually charge to 90% every night and primarily use one pedal drive so it threw me when I started seeing the brake dust show up so often.
I just washed and waxed my car and rims last night and then drove around the city a bit today (went to about 79% so not far) and barely touched my brake pedal at all, but when I got home the right rim had brake dust all over it again.
I can deal with the dust, but if it’s a symptom of a bigger problem I’d like to address it before it causes a bigger issue.

Interesting. I have been attributing it to the fact that my LFP version is less common, so most don’t charge fully. And when charged fully it’s only LFP (I think) that automatically blend the brakes in. I figure most other just don’t use the brakes as much or at all so never notice this.
I wish I had a better answer. Since you are under warranty I suggest you get it addressed or looked at at least and I’m interested to hear what they say. But mine has never had any actual issues found. And ford engineering was supposedly involved.

I am thinking of going back at some point. Just not sure what they will do next (or just try to say now that it’s ‘normal’). One mechanic said that, but one also agreed with me that I could drive any of their EV’s on the lot and never get brake dust.

 

[ron_snoop]

Interesting. I’ll look into it and be sure to post the results here. Thanks for the info.

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