Mercury Mountaineer 2004, 25,000 miles, original owner.

I performed a rear brake job and was shocked to find that the rear rotors were rusted under the brake pads in an approximate ¼” strip to such a depth that it prevented the rotors from being machined (turned) by the Ford dealer, and severely wore the pads in the location of the rust strip. Also, Outer pad (rusted rotor side) wears more then inner pad.

These rotors and pads are the original equipment and have only 25,000 miles on them, and both had to be discarded. The dealer service manager has indicated to me that this condition is common, normal and accepted by Ford and that rusted rotors under the brake pad are considered as non-warrantable. Common, normal and accepted, I was shocked! Why should rotors go bad at 25,000 miles and be discarded. I always turned rotors 1-2-maybe 3 times. What gives?


Does anyone have information if this condition is really “common, normal and accepted by Ford and considered as non-warrantable?”

I have started to look at rear rotors as I walk past Mountaineers, Explorers and other Ford vehicles. Some have had this same ¼” rust strip under the brake pad!

Any information will be helpful.



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See my post under your other thread.