Brake Rotors Done at 16K?

MadDog · Nov 3, 2008

Hey All-

So I brought by KJ in for its annual NY State inspection on Saturday and I got a call from my mechanic that she needed brakes and rotors all around. I was quite surprised by this since I've only got about 16K on the jeep. Though I've not exactly been easy on the brakes in stop & go traffic going from NY to NJ & CT, I would still think I would have gotten lots more mileage out of them, at least 25K. Now on to the strange part - my mechanic (whom I should mention has been working on my family's cars for a while, so definitely trustworthy) said that there were chunks missing from the brake rotors when he pulled the wheels for the inspection! I nearly didn't believe him until I saw it myself, there were actual large chunks missing from the inside surface of the brake disk (the side that faces towards the middle of the vehicle). I wish I had taken a picture of this, after working in a garage for 3 years in college I have never seen brake disks just fall apart like that. Has anybody else ever seen anything like this, KJ or otherwise?

$750 later (YIKES!!!), I have all new rotors and pads and she's good to go. But I still would like to know how something like this could have happened...

jnaut · Nov 3, 2008

16k is too soon. I've got 64k on mine, and haven't gotten near a brake job. So you'd have to assume some sort of abuse. My first inclination was to question the mechanic, but you say he's trustworthy, so that really only leaves the abuse angle.

Are you the original owner? This is a touchy subject when we talk about "abuse" and you're the original owner-- cause no one likes to be told they may be abusing their vehicle. One possibility is brake-riding? Ever see those people? They drive down the freeway with their brakelights on, or everytime they go over a bump their brakelights flicker. That can occur with two-foot driving-- left foot on the brake, right foot on the gas. The left foot rests and puts just enough pressure on the brakes so they get SUPER hot. Like red hot.

Are you the only driver? You might check with other drivers (family members) if you're not.

jnaut · Nov 3, 2008

Acutally, I just thought of something-- what kind of gas milage are you getting? If you're getting abnormally low gas mileage that could be a clue that something's not right. I don't see any crazy 9" lifts or 36" mudders, skid plates or hardened steel custom fab bumpers on your signature, so you should be getting right in the 17-21mpg range. If you're regularly getting anything under 14 or 15, something might have been rubbing. However, your mechanic should have noticed if anything were mechanically out of whack with the brakes aside from the damaged rotors.

ATXKJ · Nov 3, 2008

there were also some problems with calipers - I though most of it was rear but I suppose the fronts could also be affected - they weren't releasing properly - normally affects 1 rear wheel and it's noticeable.
So it's possible - but I think you would have had problems while driving.
(I'm at 64K on originals - but nothing approaching NY stop & go traffic)

JeepJeepster · Nov 3, 2008

Ouch.... Thats a bit $$$.. Could of gotten a lift and still done the brakes for that!

Some people have close to 100k on the stock brakes.. Going strong at 35k for me..

offroadohio · Nov 3, 2008

I replaced my rotors at 20k so it snot untypical to see the issue. I work at a repair shop and see ALOT of Gm's come in with rotor issues and low miles,a nd we've done a few 05+++ Chryslers witht he same issue,. The rotors rust fromt he inside out and develop rus tpits that are to deep to turn out.

I was down to 4mm of pad in the rear when I did mine at 20k. 2mm is considered toast.

MadDog · Nov 3, 2008

Thanks for the replies guys. For the record, I don't think that I've been abnormally tough on the brakes and am definitely not the kind of driver that rides the brakes on the highway or taps them constantly (no more than is necessary in NY stop & go traffic). In fact, I go out of my way to allow natural deceleration as much as possible before I have to hit the brakes, so I am fairly certain that it's not my driving (though you never know, there's always a chance...). Also for the record, I am getting 18-20 highway and 15-17 local so the MPG's are not really abnormal either.

That said, when offroadohio said that rotors were "rusting from the inside" it hit me, when I looked at the rotors and at the big spots of missing metal in the normally smooth surface that's exactly what it looked like, every part of the metal looked like it just rusted and corroded away including the gaps. It just doesn't really make as much sense that they would rust so quickly, but being on long island (proximity to ocean) and going from hot weather to cold could cause excess wear when coupled with some heavy usage commuting. I just hope the napa rotors they were replaced with last longer. I have GOT to learn how to do this type of work myself, any recommendations on how to learn to work on brake pads & rotors?

flair1111 · Nov 3, 2008

MadDog said:
Thanks for the replies guys. For the record, I don't think that I've been abnormally tough on the brakes and am definitely not the kind of driver that rides the brakes on the highway or taps them constantly (no more than is necessary in NY stop & go traffic). In fact, I go out of my way to allow natural deceleration as much as possible before I have to hit the brakes, so I am fairly certain that it's not my driving (though you never know, there's always a chance...). Also for the record, I am getting 18-20 highway and 15-17 local so the MPG's are not really abnormal either.

That said, when offroadohio said that rotors were "rusting from the inside" it hit me, when I looked at the rotors and at the big spots of missing metal in the normally smooth surface that's exactly what it looked like, every part of the metal looked like it just rusted and corroded away including the gaps. It just doesn't really make as much sense that they would rust so quickly, but being on long island (proximity to ocean) and going from hot weather to cold could cause excess wear when coupled with some heavy usage commuting. I just hope the napa rotors they were replaced with last longer. I have GOT to learn how to do this type of work myself, any recommendations on how to learn to work on brake pads & rotors?

google it and study it very well. then if you know a friends who can watch you and help when needed, try it yourself.

try jacking up the front on both sides and block it underneath or jackstands. take both wheels off. then do one side at a time using the other side as a reference in case you get screwed up. do the back the same way. drums might be on the back depending. just use one side for a reference again. it is easy to do once you do it once or twice.

jnaut · Nov 3, 2008

Maddog, sounds like your driving style is about as conservative as mine. I live in stop-and-go Seattle traffic-- I'm not sure if you're in NYC or just in Ny, so my traffic might be even worse than yours. So no doubt about it, 16k is way... wayyyy too soon. But OffRoadOhio got me to thinking too. You guys salt the roads in the East, no? Also you note your long island location. I'm on Puget Sound so I'm surrounded by salt water as well, but Puget Sound doesn't have surf- so we don't have that salt haze that's prevalent on the coast.

As far as doing the work yourself, brakes are probably one of the easier things to do on a vehicle-- as long as you're merely replacing existing, working components. And you shouldn't have to replace your rotors (your problem notwithstanding), usually just your pads. You'll have to occasionally have your rotors turned and deglazed which you can have done at a good shop. But the labor is fairly easy. A lot easier than with drum brakes (in my opinion).

You might consider slotted rotors if you suspect your problem may be road salting.

jnaut · Nov 4, 2008

One final thought, maddog...

You have an '06 with only 16k? That's pretty light mileage for almost three years old. I'm wondering if salt air is your problem, and you're parked a lot leaving salt buildup on the rotors. Everytime you brake, you 'clean' your rotors off. If your jeep sits idle for days or weeks at a time, you might consider shooting some clean fresh water through the rims at the rotors every so often.

VTNomad · Nov 4, 2008

Warranty

A 2006 with only 16k? That has to be a warranty fix. This problem wouldn't be included in the normal 'wear and tear' category. Your mechanic should have known that.

MadDog · Nov 4, 2008

Actually I bought her brand new exactly two years ago when 07's were rolling onto the lots and 06's were going for a steal, so she's only two years old with 16K. Though I see what you're saying, perhaps the vehicle sitting on the lot for so long prior to me buying her contributed. Plus with my job (consulting), she has sporadic periods of usage where I will need to make a 1000 mile trip around the tri-state area and then she'll sit for 2-3 weeks. In fact, since July she only moves on the weekends since I commute to NYC by train so this is starting to make more and more sense. Also, we do salt the roads here during the winter and there have been times where she's sat for a few weeks at a time before I had the chance to clean her up. So now I know, I'm going to have to be more careful with all of the various conditions around here with this set of brakes.

I don't think that this would have been covered under the warranty because brakes are a wear item. Yes 16K is way premature, but I still think the stealerships would deny any claim to warranty over that. Not to mention that I have now refused to give my business to two of the stealerships in my area for various reasons related to gross incompetence.

VTNomad · Nov 4, 2008

Brakes

I really think this is a warranty item...or should be.

Brakes are a wear item, but there is no way that brakes should should this kind of damage, with the amount of miles that you have, without some type of factory defect. They're not worn, they're physically damaged, and they're not damaged from something that you've.

That damage isn't being caused by normal wear and tear. You either have a defective part, which could be anything from the rotors, calipers, pads, master cylinder, etc. The defective part could cause damage to other parts, warranting their replacement under warranty as well.

At a minimum, I would want the rotors and pads replaced immediately, and the calipers thorougly checked out. I would definately keep an eye out for any problems in the future.

Brake Rotors Done at 16K?

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