Brake Rotor Failure

[MJM]

I changed my front brake rotors this past weekend 04 100 with 106k.
These were the original rotors and still had life left in them but the brakes were pulsating a little so it was time. When the drivers side was removed the rotor split into two parts all off the vents were rusted so bad that it caused the rotor to fail.
I am happy this happened during maintenance and not will driving the family. The truck is in Ohio but not rusty at all underneath. A word of warning to those in the NE about the dangers of older rotors on trucks.
I have changed the pads on this truck about 3 times over the past few years I have owned this truck since almost new.

All new OEM brake stuff sourced from Beno. If the rotors lasted this long why not use the same.

 

[hoser]

Did you happen to measure the rotor thickness between pad changes? Or the thickness of the unbroken rotor?

 

[bamachem]

... I have changed the pads on this truck about 3 times over the past few years I have owned this truck since almost new...

Really? That's a LOT of pads for a 100-series. They usually last 80k-100k on the trucks I've owned, and it's usually the rears that go first. Strange that you've gone through 3 sets in under 100k.

 

[Supra88]

I had 155,000+ miles on my original rotors, both front and rear. They were both still in spec when I replaced them with new OEM rotors.

Did they split from the force it took removing the hubs? Did you do them yourself? If not, are you sure your mechanic didn't beat the tar out of them removing hubs? Just a thought.

 

[MJM]

Ok

So three sets of pads were installed on the fronts. Original and then 2 replacements.
Rotors were stock and still within spec they just pulsated. The last set of pads were only on the truck for 10K and they had a lot of life left in them.
Rear rotors were replaced by dealer at 60K (I was out of town and the dealer upsold the wife)

They split when being removed from the hub not a crazy amount of force to brake them just your standard hit with a mallet. Maybe I hit them just right to split it not sure but I was just surprised how rusted they were considering the lack of rust on other parts. I wonder if the calcium deicer they use around here is extra corrosive to the raw steel of a brake rotor.

I would suggest if you are in the NE change out the rotor at 100k regardless of the thickness.

 

[2001LC]

Really? That's a LOT of pads for a 100-series. They usually last 80k-100k on the trucks I've owned, and it's usually the rears that go first. Strange that you've gone through 3 sets in under 100k.

I'm glade you post this, my front pads have 87K miles and 4.5mm avg width to go, rear pads went after 60K miles. I've always looked for front to go first and was thinking somthing wrong.

******** I wonder if the calcium deicer they use around here is extra corrosive to the raw steel of a brake rotor.

I would suggest if you are in the NE change out the rotor at 100k regardless of the thickness.

My last SUV rust-out, I used auto wash letting others clean it. I now wash at coin op and get underside & wheels every time.

The road salt are bad and even worst is the chemicals as they stick. Even my garage floor is trashed form the chems.

I'll now pay more attention to washing brake rotors, thanks for the heads-up.

 

[BackToTheBog]

They split when being removed from the hub not a crazy amount of force to brake them just your standard hit with a mallet.

It's possible that the corrosion created a notch condition (a weak spot where fractures start). This could have been magnified by over-tightening or uneven torquing of lug nuts.

 

[Bloomer]

When doing some suspension work recently, i noticed the vents on my 2006 are very rusty. Much more rusty than I would have expected for a vehicle with less than 50,000 miles (albeit it is 7 years old). After reading this thread am now thinking new rotors need to move up on the "to do" list.