Front rotors- chronic warping problem

Dadwagon

Veteran Member
Joined
May 20, 2018
Location
Canton, ct
TDI
2004 Jetta Wagon
Hey all,
I have a super high mileage 04 wagon with problematic front brakes.

The rotors warp and cause severe shaking at just about any speed.

I have done many brake jobs, not just on this car, and because of the same problems prior to doing them last, i was extra cautious to follow all the guidelines to prevent warping, and made sure I:

Properly lubing and seating the caliper slides
Properly torquing the lug nuts
Using good quality rotors and pads from power stop.

No luck- they have about 15K on them and they shake and shutter like Elvis.

I think someone suggested i check the rear axle bushings? Is that the next step?

My brother yesterday pointed out the back wheels are slanted out (from top to bottom). Not sure if that’s another indicator of bad bushings?

Could something in the rear be causing all the shaking up front?

Any help is much appreciated

Dave
 

Mongler98

Top Post Dawg
Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
MANY reasons why rotors warp, 90% of the time its due to higher than normal clamping pressure. Did you put any grease, oil or lube of any sorts on the wheel bolts/ studs? that is a BIG no no
Proper torquing is KEY to the life of a rotor.
90ftls of torque on a dry clean bolt and wheel and hub will yield about 1800 - 2000 PSI of clamping pressure, Putting oil on the threads of the same set up will jump that PSI up to a freaking 8000+ PSI of clamping pressure. this WILL warp your stuff.

Also old cars have old parts that have been sitting in a warehouse for 20 to some times 20 years and the weight of them being stacked up in pallets will warp them over time, ESPECIALLY DRUMS

Are you getting a quality rotor or some cheap POS from china on ebay or an autostore?

Old calipers that dont use pad shims will wear out over time and that small amount of wear where the pad slides will cause it to bind and binding pads will put UNEVEN heat on one side of the rotor vs the other, this will cause a warp as well over time.
 

03TDICommuter

Veteran Member
Joined
Dec 8, 2016
Location
So. Cal
TDI
01' NB, 5spd
You want to fix this for good? Check rotor runout and correct any issues so you have near zero runout or 0.002" or less. That will solve it.

Runout is probably from corrosion on the hub-rotor mating interface.

I went through this and only after correcting runout to near zero, I'm vibration free even now after I think 20K miles. (and this is with cheap Wagner rotors)
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
Look at the rear bushings on the control arms in the front suspension. If they're shot, (split or cracked) the car will behave like the rotors are warped. Same could happen if the rear axle bushings are shot or the shocks are totally worn out.
 

03TDICommuter

Veteran Member
Joined
Dec 8, 2016
Location
So. Cal
TDI
01' NB, 5spd
Top