2003 XLS Brake Rotor Problems

[PABear]

Hi All,

(I think I posted this in the wrong forum before)

I'm seeking some advice regarding my 2003 Explorer Brake rotors. I've owned this SUV since new, about 3 years now, and it has 28500 miles and "lightly driven" - No off-roading, towing or heavy braking.

In the last 2 years I've had my front rotors changed 3 times and rears once. I experience a shake and vibration when they are close to be changed. Each time they have been covered under warranty. However, my concern is that my warranty is about to run out in a month. My last rotor change was yesterday (fronts).

I've only had this serviced at the dealer I bought it from and never anywhere else. Each time I'm told that the rotors are warped and need replacing - "don't worry its covered under warranty." I've asked each time why are they in need of replacing so early and they seem to want to point the blame all kinds of factors, me (my driving habits), using brake covers (never), using wheel cleaner (never), towing (never), other drivers (next to never), weather, steep roads... I could go on.

Now I face a situation where I will be out of warranty and looking at changing these out of pocket. Based on the past performance I can only expect to change these twice a year.

Ford Customer Service wasn't helpful, they refer to written warranty and pass it to the dealer. The Service Manager just lists reasons why they could go bad. When I asked specifically how many Explorers like this are having the same problem, he dodges the question. I can't imagine other owers coming in as often to have the rotors changed this often and not be upset about it.

My two options I see now are replace the rotors with aftermarkets next time they fail, or try and sell it off and go through that nonsense.

Aside from these problems, I've had the Liftgate replaced (cracked), the front hood repainted (pealed off paint and began to rust), and The ABS sensor replaced 3 times.

I'd really like to hear some experiences and opinions. My Searching on the internet has led me with few experiences to draw some conculsions from.

 

[White97Jimmy]

From what I understand, whatever rotors that Ford uses are pretty crappy in terms of durability. I've heard that a few times on this board, as well as my local brake shop.

I experienced the same "shaking" feeling while braking and took my truck in to the local brake shop. They said that every Explorer they have worked on is right at 30k miles. He asked how many miles were on mine, and I said 29,800. He must work on a lot of Explorers!

 

[mlm43]

The complete story

I started to replace rotors and pads on my 2002 XLT, but could only complete the front brakes without help (a local garage bailed me out and made some $$). The rear rotors could not be removed due to the rust ridge in the emergency brake drum. In order to remove the rotor / drum, the emergency shoes must first be adjusted to reduce the shoe circle size, as you would with any conventional drum and shoe assembly. The trick here is that the adjuster, yes there is an adjuster, is located behind a knock out plug on the brake backer plate. The knock out is not at "6 oclock" but at "7 or 8 oclock". My local Ford dealer was not really aware of the knock out, at least not at the parts desk. I have yet to locate a plug that can seal what is now a 1.5" hole in the backer plate. Any suggestions?

As you might expect, the shoes and adjusters were shot, and had to be replaced. All this for emergency brakes I do not use!

Marty

 

[JasonF]

I don't know why your explorer is going through rotors at such a fast rate. My 04 has 35,000 miles and original brakes. My only complaint is at highway speed under hard braking i get a slightly rough feel from the rear brakes. I don't know what exactly is causing it but it hasn't been bad enough to warrant further investigation.

I seem to remember when my mother had her brakes done on the old ex (out of warranty) they said that the expensive replacement rotors had a lifetime guarantee. So you may want to check into whether they use the same rotors for warranty service as when you have to buy them.

Just one thing to think about; you say "'lightly driven' - No off-roading, towing or heavy braking." You do understand that prolonged light braking can quickly overheat the brakes? Coasting down a hill with your foot lightly on the brake is not better for or easier on the system than hard braking. You are better off using a series of moderate brake applications with coasting in-between so the system can cool down.

Since there are so many ex's out there that are not having problems, and you have had several sets of "bad quality" parts put on, it certainly does make it seem like there is something about your particular usage pattern that is causing the trouble. I hope you can figure it out!

Jason

 

[bulldog3531]

Also the possibility of the warped rotors may be due to over torque on the wheel lug nuts.

 

[Joe_R]

Original brakes had 60K. I just replaced my front brakes with Ford OEM pads and rotors. No shake, no shimmy. I understand when the dealership replaces rotors and pads, they use Motorcraft parts which seem to be a different compound then the OEM parts. There must be something else affecting your brakes. ps. did they replace them under warranty because they were warped or is brake maintenace part of a warranty package you bought?

 

[Bill Kemp]

Below is a link to an article about "warped rotors" I would consider it a MUST READ.
This could well solve your problems.
http://www.stoptech.com/tech_info/wp_warped_brakedisk.shtml

 

[mhochman]

I was having what I thought were warped rotor symptoms. I pulled the wheels off to check the run out, the left was .002 and the right was about .004 out. That does not seem to be to far from straight. While I had the wheels off, I noticed what seemed to be loose calipers on the mounting bolts to the back plate. I checked the bolts that hold the calipers to the back plate and they were tight. I removed them put some grease and retightened them which seemed to take MOST of the loose fit out. I took it out for a test drive and the warped rotor feeling has been reduced by 70%. I still feel it but no where near as bad. Any thoughts???

 

[coled43]

So, your caliper bolts were were binding in the threads and not getting properly torqued? This is a pretty old thread but, I read the article that was linked to in the previous post. Good reading.

 

[High_Order1]

sure this has been covered, but just in case, how much crap is in your vehicle? Three adults and a bunch of junk in the rear quickly adds up. More weight = more work for the brakes.

-Shawn

 

[aspitaletto]

make sure you are setting the TQ on your wheel lugs correctly !!!!

most shops over-tighten lugs because they use impact guns.

get yourself a decent Tq wrench, and set the lugs to 60ft/lbs, then set them to 90ft/lbs

 

[aspitaletto]

!

 

[jrford]

My '04 hit 35k and i have the same vibration with the brakes started about 28k and got worse. Just did the fronts this weekend. A while back I talked with a service rep, and he said Ford was only turning them and putting on new pads.
When I took them into the autostore the Disc's where measured at .52 with Factory at .59, only .07 worn or 10% still a lot of beef left. The pads looked shot however. So i only turned them and added Raybestos Prem, semi-Metalic pads (only place open on Sun) but so far the braking is much improved. I guess i'll see if they warp again, but I have a feeling its the pad's and not the rotor that causing the problems.

Once I break in the front i'm going to do the rears too with the same pad. The rear discs seem true and with all the problems with the ebrake, i think i only going to swap out the rears pad and not turn the rotors.