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SRO2000X · 2003-11-16T23:48:54-06:00

Hi all, The subject should read " Warped Rotors" I bought a new 2000 X Limited V10 4x4 and after 10K mile my brakes started to pulse. I was out of town and stopped by a Ford dealer to have them check the brakes and the Steeltex tires. It was right when all the Firestone trouble started. Of course they said there was nothing wrong and I went on my way. Of course the brake problem only got worse. By 22K mile the pulsing was so bad I could launch a drink out of the forward cup holders! So I dropped it off at a local dealer for repair. They called me back and said they would turn the rotors and replace the pads for ONLY $700.00!! When I told them the truck was still under warranty they said the brakes weren't covered past 12K miles! So I showed them the work-order from the out of town dealer that I had gone to at 10K miles but they still balked. So I called Ford. They said they would cover the cost of turning the rotors and replacing the pads. But I didn't want the warped rotors, turned or not. I told the dealer I believe that once they warp they're junk. And if you do turn them, not only does it require a LOT of turning to get them true which really reduces the life of the rotor, they will only warp again because its a manufacturing defect in the rotor that caused the warp in the first place. Also I didn't think it was fair that my NEW truck warranty wouldn't cover NEW parts. The dealer refused to replace the rotors so I called the Ford store that sold me the truck and told them the story. They said bring it to them and they will replace the rotors and pads, no problem. So I called the guys that still had my truck and told them to put it back together so I could take it to the other dealer to get it fixed right. This guy goes nuts! He tells me if my selling dealer replaces the parts he will call Ford and report them for fraud! I couldn't believe it! As much as I wanted to go get my truck and tell this guy to stuff it I just didn't have the time to go get it and start the process all over again. So I told him I would accept his offer to have the rotors turned but if they started pulsing again he would have to give me all new parts. Well we all know what happened. Two days later they were still pulsing and I made them give me new rotors and pads. I don't think they even turned them right in the first place. It would have cost them WAY less to fix it right the first time. The point of all this is I now have 31K miles on my new rotors and they don't pulse. As I said above, I believe that once they warp they're junk and should be thrown out! I have read about many owners that have had to turn there rotors every 10K miles and I think they will never get rid of the warping till they get rid of the bad rotors. This may explain why some owners have even had warped ART rotors. Some times you just get a bad part. I would think the quality of the ART rotors is much better that the OEM but you could still get a bad one every once in a while. I read a reply from ART about an owner with warped ART rotors and they said to check "this and that" to try and find the problem and that they had not had a rotor warp for no reason. Maybe. But it could also just be a one in a million bad part. I think the OEM parts aren't as good so we see this much more often. My rotors don't pulse so I don't need to replace them. But if I did I would probably get the ART rotors because odds are they are right from the start and wont warp. But if they did I would replace rather than turn them. I have turned rotors that were worn and they work fine but warping is another thing. I cant see any reason why a warped rotor would stop warping just because you cut it down. If you get a good set, keep em. If you get a bad set, get rid of them. The sad thing is the Ford should replace a warped rotor, but as we all know they wont do it without a fight even when your truck's still in warranty! I wonder if ART or any of the other manus will replace a warped rotor? This is just my opinion on the warped rotor problem. And oh by the way, Ive never used a torque wrench on my lug nuts and they have been installed from time to time with an impact wrench. Hope this may help someone with this problem.

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Ford Excursion Forums > Ford Excursion V8, V10, and Powerstroke > Excursion Discussion

Warped calipers

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Sherri Jones

• Webster, FL, USA

• Registered on 12/3/2003

• 2 posts

Posted:12/3/2003 01:02

edited 12/3/2003 16:13

Edward Newman

• Long Island, NY, USA

• Registered on 12/9/2003

• 18 posts

Posted:12/9/2003 10:31

I have dozens of Fords in my company. Bottom line... BIG truck driven hard and fast, you WILL warp the rotors and suck down pads. There are options in different pad materials and vented discs that WILL help, but everyone has a compromise.

Michael Gail

• Sierra Madre, CA, USA

• Registered on 5/1/2003

• 138 posts

• 1

Posted:12/9/2003 12:32

My '02 is at the dealership as I write this. It has 23,000 miles on it and the rotors are warped. Dealer refuses to resurface the rotors under warranty as the rotors are "wearable" parts and are only covered by the 12 month, 12,000 mile warranty. I paid approximately $2,000 for the extended 100K warranty but the "wearable" parts are not included. It seems to me that the rotors should be covered. The pads are the "wearable" parts. Has anyone else been able to get Ford to either resurface of replace the rotors under warranty at more than 12000 miles?

Mike
'02 EX, Limited, 4X4 , PSD, Nitto, Terra Grapplers 295/16, K&N Air Filter, Billet Grill, Hidden Hitch. Magnaflow SS Exhaust system with 3.5" downpipe, 4" main and 5" tip. Banks Six-Gun Power Module, Banks TransCommand.

E. Long

• Subscriber since 1/1/2001

• Atlanta, GA, USA

• Registered on 1/23/2001

• 2,229 posts

• 1

Posted:12/9/2003 16:48

Quote:

Mike,

You'll have to bend over and take it in the rear on this one. Ford doesn't budge on this one...ask me how I know. 12K is the limit, no ifs ands or buts about it.

It's all about the torque on the lug nuts. Make sure they torque the lug nuts to spec. I torque mine to 150 ft-lbs and no longer have warping issues.

-Eric

'67 Galaxie 500 - 390 FE, .030" over, FE to AOD adapter, disc brake conversion. The Daily Driver.
'00 Excursion - 7.3L PSD, LANDYOT Gen-II Radius Rods, Factory Tech Valve Body, 200K+ miles and going

Michael Gail

• Sierra Madre, CA, USA

• Registered on 5/1/2003

• 138 posts

• 1

Posted:12/9/2003 17:24

Eric, thanks. I originally took my EX to the dealer at 10,000 miles and was told they would have to resurface the rotors. I wasn't too happy with the idea and [unfortunately] put it off until they got worse. Now, it's over the magic number of 12,000 and I have to foot the bill.

Mike
'02 EX, Limited, 4X4 , PSD, Nitto, Terra Grapplers 295/16, K&N Air Filter, Billet Grill, Hidden Hitch. Magnaflow SS Exhaust system with 3.5" downpipe, 4" main and 5" tip. Banks Six-Gun Power Module, Banks TransCommand.

Dave Sullivan

• Kitchener, XX, Canada

• Registered on 2/27/2003

• 199 posts

Posted:12/9/2003 19:36

The 12 k mark is clearly when ford expects their product to become unreliable.

I'm no expert but I was looking at my old rotors and pads and have come to the conclusion that there is not sufficient surface area in the picture.

Perhaps someone out there is a brake engineer and can enlighten us all with a better education.

I think the rotors are to thin to start. I also think that they are much to susceptible to corrosion in the area between the two discs. The disc surface is very narrow and the pads are too short and too narrow.

I think that given that each disk assembly has to handle at least two tons of vehicle apiece, that they are much too small and are not likely able to handle the heat being generated.

If I compare the surface area of one of the rotors on my wifes focus wagon, which weighs considerably less, to the rotors from the EX, I find that there is a larger area for less weight on the focus rotors and pads.

Having said all that, the focus rotors only lasted 20k killometers. 12k miles. (disenchanting) No warping though, just worn out pads to the point of grinding.

Take heart folks. The guy at my local auto parts store said that ford and GM are going thru brakes big time.

But the cost is totaly bizzar.

By the way... can anyone tell me the difference between premium and non premium rotors and pads? other than 30 dollars vs 100 dollar rotors? The folks that sell them don't seem to know.

Dave.

Charles Fraley

• Lawrenceburg, IN, USA

• Registered on 12/11/2003

• 6 posts

Posted:12/11/2003 21:29

I have a Y2K Excursion limited with the 7.3 Diesel engine and is a 4X4. My question is, and please excuse my lack of knowledge on the subject. When I apply the brakes the vehicle pulls hard to the left. I also hear a repetitve noise as the tires roll and the pitch changes depending on the speed. Anyone know why it pulls or what could cause the mild thumping noise? Any help would be greatly appreciated.

Weatherlite

• Mountain Home AFB, ID, USA

• Registered on 10/21/2002

• 133 posts

• 1

Posted:12/12/2003 09:41

Charles,

Pulling to either side means one of your calipers is not working. Since it's pulling to the left that means that the right side caliper is not working right. Sounds like it is frozen. Same thing happened to mine. The slider pins are covered with a rubber boot that dry rots and allows water into the pin area...they get rusty and then seize up.

As for the tires...is this just something that has started recently? The problem is an out of round tire(s). How you fix an out of round tire I have no idea...don't think it's possible. However, the reason I asked if this started recently is that it's starting to get cold out. When tires sit for awhile in cold weather the part that flattens out against the pavement while parked tends to stay flattened out for awhile. Once the tires start warming up they round out. No danger in this situation. If you're new to vehicles with tires this large it isn't uncommon.

Hope that helps!

Mikie

Charles Fraley

• Lawrenceburg, IN, USA

• Registered on 12/11/2003

• 6 posts

Posted:12/12/2003 10:24

Weatherlite, thanks for the help. I will have the brakes checked. I am new to this vehicle and it has recently turned cold here so I wil see if the noise changes. As far as the caliper what type of cost are associated with replacing or repairng? if you know

Weatherlite

• Mountain Home AFB, ID, USA

• Registered on 10/21/2002

• 133 posts

• 1

Posted:12/12/2003 12:40

Really the costs depend on if you get dealer new, parts store new or used. Also, it depends on if both section of the caliper slide are shot or if just one side needs replacing etc etc. I fixed mine for about $60 but I've heard of others who had to replace more stuff and it ran over 120.

Good luck.

Ford Excursion Forums > Ford Excursion V8, V10, and Powerstroke > Excursion Discussion

Warped calipers

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