Warped rotors AGAIN!?!?!

[rhougey]

What is or are skimmed rotors?

I think he means they took almost nothing off.

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[Jarratt]

The regen brakes are an independent system. They don't use the brake rotors, so regen braking couldn't be the source of your warped rotors...

My dealer didn't know this. I had to send them the TSB that F issued. The last PP is particularly instructive. They wanted to charge me an arm and a leg for rotor work, going down a steep hill in N (no regen) w/aggressive braking did the trick.

he "sticking issue" where brake pads bond to the rotors is addressed by Technical Service Bulletin (TSB) 22-2023. [1 (https://www.macheforum.com/site/threads/brake-pads-sticking-to-rotors.18480/), 2 (https://www.macheforum.com/site/threads/brake-pads-sticking-to-rotors.18480/)]


This bulletin supersedes the earlier TSB 21-2206 and applies to 2021–2022 Mustang Mach-E vehicles built on or before January 6, 2022. [1 (https://static.oemdtc.com/TSB/MC-10209201-0001.pdf), 2 (https://static.oemdtc.com/TSB/MC-10209201-0001.pdf)]





Key Details of the Bulletin:


• The Problem: Due to high-quality regenerative braking, the mechanical brakes are used less frequently. This can cause brake pad material to oxidize and bond (stick) to the rotors, especially after the vehicle gets wet (rain or car washes).


• Symptoms: Drivers often notice a "clunk" when first moving, followed by a vibration, pulsation, or "thumping" sound while braking.


• The Fix: The official service procedure involves replacing the brake pads with a revised part and resurfacing (machining) the rotors to remove the bonded material.


• Warranty Status: This repair is generally covered under the New Vehicle Limited Warranty (3 years/36,000 miles), provided the vehicle is still within that window. Some owners have reported challenges getting it covered if their vehicle is older than one year, as brakes are sometimes classified as "wear and tear" items. [1 (https://static.oemdtc.com/TSB/MC-10209201-0001.pdf), 2 (), 3 (), 4 (), 5 (), 6 (), 7 (https://static.oemdtc.com/TSB/MC-10209201-0001.pdf), 8 (https://www.macheforum.com/site/threads/brake-pads-sticking-to-rotors.18480/), 9 (https://www.macheforum.com/site/threads/brake-pads-sticking-to-rotors.18480/)]





Maintenance Tip to Prevent Sticking:


To prevent rust buildup, owners recommend occasionally shifting the car into Neutral while slowing down from higher speeds. This disables regenerative braking and forces the mechanical brakes to engage, effectively "polishing" the rotors

 

[Keytone]

The Fix: The official service procedure involves replacing the brake pads with a revised part and resurfacing (machining) the rotors to remove the bonded material.

Though I have 2023-2, this can explain why the brake thudding returned to my car ~3 months after the dealer, in November, resurfaced my rotors but did not replace the brake pads.

 

[E90alex]

I had the brake vibration on my 2025 GT. Dealer replaced front pads and resurfaced the rotors at my 10k service.

Since then I’ve been making a conscious effort to use the brakes in neutral at least once a day.

Even so, the vibration is back now 2000 miles later

So I’ve given up on it and won’t bother with the neutral braking sho anymore since it didn’t help. Ford will just get the car back at lease end with vibrating brakes. Or if I keep it then I will look into aftermarket brake options.

 

[Keytone]

I had the brake vibration on my 2025 GT. Dealer replaced front pads and resurfaced the rotors at my 10k service.

Oh no, I'm then wondering if it's another cause we are facing - over torqued lugnuts or uneven wheel mounting?

 

[dolvio]

Oh no, I'm then wondering if it's another cause we are facing - over torqued lugnuts or uneven wheel mounting?

it’s something with the design in my opinion. Mechanical parts are meant to be used and problems arise when they are not especially when things get hot/cold/wet. I switched off my one pedal and just use the car like my other cars and no problems anymore.

 

[RandyMache]

it’s something with the design in my opinion. Mechanical parts are meant to be used and problems arise when they are not especially when things get hot/cold/wet. I switched off my one pedal and just use the car like my other cars and no problems anymore.

That won't help the situation. Even without using one peddle drive, pressing on the brake peddle acts the same way. Still uses regenerative braking before or unless a hard stop is needed.

 

[dolvio]

That won't help the situation. Even without using one peddle drive, pressing on the brake peddle acts the same way. Still uses regenerative braking before or unless a hard stop is needed.

Yes it absolutely does help. You are continually activating the calipers, pads etc

 

[Keytone]

Yes it absolutely does help. You are continually activating the calipers, pads etc

No, only by your choice to apply extra brake predal pressure to bypass the regenerative braking and thereby force the car to enage the brake calipers.

 

[dolvio]

No, only by your choice to apply extra brake predal presure to bypass the regenerative brakiing and thereby force the car to enage the brake calipers.

If you’re not in one pedal you will be forced to use the brakes more often. Do it or don’t but that will help this issue. I’ve had a ton of problems with my brakes so far.

 

[Keytone]

If you’re not in one pedal you will be forced to use the brakes more often.

Excuse me, but that is incorrect. One is forced to use their brake PEDAL but that does not equate to the use of the brakes unless one applies extra pressure upon the pedal to brake faster.

One could easily be driving without one-pedal driving and only ever have the car engage the brakes upon the instance of a full stop - no practiced vehicle difference than of one-pedal driving.

 

[dolvio]

Excuse me, but that is incorrect. One is forced to use their brake PEDAL but that does not equate to the use of the brakes unless one applies extra pressure upon the pedal to brake faster.

One could easily be driving without one-pedal driving and only ever have the car engage the brakes upon the instance of a full stop - no practced vehicle difference than of one-pedal driving.

Okay. You do you and I’ll do me and let’s report back in another 3 months and see who has more issues with their brakes .

 

[RandyMache]

Yes it absolutely does help. You are continually activating the calipers, pads etc

No you are not. A normal, easy push on the brake pedal always uses regenerative braking first. It does nothing different then using one peddle drive. You can ask anyone on this forum or call your dealer. These questions have come up before and even Ford confirms this.

 

[Tomm]

I had a C-max hybrid and now the MachE. In two pedal drive I almost always get 100% brake efficiency. It must be using regen in two pedal drive for me to do that.

 

[RandyMache]

I had a C-max hybrid and now the MachE. In two pedal drive I almost always get 100% brake efficiency. It must be using regen in two pedal drive for me to do that.

100% true

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