Brake rotor uneven wear-corrosion

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Thread: Brake rotor uneven wear-corrosion

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    Brake rotor uneven wear-corrosion

    Hello everyone. I service and maintain vehicles for a fellow who has a 2012 Fiat 500, purchased new, non-turbo, automatic, daily driver, just under 30k miles. Warranty repairs of note include leaking coolant hoses at radiator (repaired with new clamps), and clunking front suspension (repaired with new front struts). While recently performing the yearly State Inspection, I noticed slight-moderate brake noise and pulsation. Upon visual inspection I found uneven wear and corrosion on the brake rotors. It was worse on the rears, and on the inside surfaces, but also visible on the outside of the rears. There was about 50% brake lining remaining. See images. I replaced all rotors and pads and the pulsation and noises were eliminated. All caliper pins were well lubed and pad sliding surfaces were in good condition. Any thoughts on what causes this abnormal wear on the rotors? Name:  DSCF2907.JPG
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    That's a lot of corrosion. I don't know what caused this, so I only have questions.

    It sounds like a warped rotor, huh?. I wonder if the owner has ever let his car sit unused, for an extended period? The corrosion looks excessive. I also wonder if the owner has ever experience an occasion of maximum braking when the brakes were already hot? Did he experience an 'event' while driving? Are his tires wearing evenly?

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    Quote Originally Posted by andylarry View Post
    All caliper pins were well lubed and pad sliding surfaces were in good condition.
    My first reaction was that the calipers are not sliding smoothly on their pins and are hanging up. It's weird that it would happen on all 4 rotors (well three, and the fourth to a lesser extent). I doubt all 3 calipers would hang up in that same way. The next thing I wonder is if there is some problem with heat treat on the rotors (either in manufacture, or as Brian suggests, from a hard stop). Maybe someone who's a Fiat tech can weigh in...

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    Quote Originally Posted by Doohickie View Post
    My first reaction was that the calipers are not sliding smoothly on their pins and are hanging up. It's weird that it would happen on all 4 rotors (well three, and the fourth to a lesser extent). I doubt all 3 calipers would hang up in that same way. The next thing I wonder is if there is some problem with heat treat on the rotors (either in manufacture, or as Brian suggests, from a hard stop). Maybe someone who's a Fiat tech can weigh in...
    I had to replace all four rotors on 2013 last fall, about 50,000 km or less than half what my Jetta's brakes lasted. I think with the VW I went 130,000 km on the original rotors. Must not be the best rotors available that Fiat is using but they sure know how to charge for them.

    Gerhard

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    Andy, I have seen better rotors on cars in a junk yard. I would think that them rotors have not been treated correctly from the supplier or maybe used the cheapest material to make them and a couple of harsh winters in PA finished them off too early. My rotors on my 2012 AB started to show rust on the back just like yours at around 10k and they have never seen salt or snow just water since I had the car in Arizona.

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    I agree on the junk yard assessment. Definitely Winter salt and chemicals combined with no washing or rinsing along the way. Good news is after market rotor sets seem to be available for a reasonable price.

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    Tedolph (05-17-2016)

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    Obviously the user parks the car in a salt water pond.

    TEdolph

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    Thanks for the quick replies! The car sees mostly city-urban drive cycles, with 1-2 out-of-town interstate trips of 100 miles or more a month. The owner may take a 1-2 week vacation 2-3 times a year. He is an adult mature driver that doesn't drive like a wild teenager. The car still rides on it's original tires. As I said, the sliding pins were still fully lubed and working well, and the brake lining had maybe 40-50% remaining. Sure, here in PA the roads are well salted for 4-5 months a year. But I don't see this on all the cars that I service, especially a newer car with less than 30k mileage. I'm leaning more towards poor quality steel and / or poor rotor-brake pad material matching. My wife drives a 2001 BMW 530i about 35k a year and my college age daughter has a BMW 330i that is driven only 4-5k a year and sits (outside) for months at a time, and the rotors on those cars never look like this. Keep the guesses / explanations coming!

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    Quote Originally Posted by multiair View Post
    I agree on the junk yard assessment. Definitely Winter salt and chemicals combined with no washing or rinsing along the way. Good news is after market rotor sets seem to be available for a reasonable price.
    That wasn't the case with my car, really was driven much the same as the VW I had before the 500 so I think it is sub-par parts. My wife's car sits all winter and it didn't get that type of damage.

    Gerhard

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    Must be a bad batch of parts. My rotors look pristine after 30k mi.

    Tedolph

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