Affinia Global Brake & Chassis reports it recently discovered a serious potential brake safety concern regarding the replacement and use of certain imported brake rotors that are significantly different from the Original Equipment (OE) rotors they replace.
These replacement rotors deviate widely in thickness, air gaps, vane configurations and overall have a significant reduction in the effective thermal mass or weight. These changes to the rotor makeup and design do not conform to the OE specifications and adversely affect the product performance leading to the possibility of rotor failure and braking system problems, according to Affinia. Brake rotors are a safety-related component and should never be compromised from OE design without engineering validation.
As a result of these changes, lightweight rotors run hotter and the brake system cannot absorb and dissipate that heat properly. Therefore, the heat creates thermal stress and strain, which induces cracks in the rotor. These cracks lead to, among other things, longer stopping distances and potential wheel lock-up, Affinia states.
The heat is also transferred to the brake pads, caliper pistons, and brake fluid and can cause premature wear of these components. Ultimately, left unrepaired, these thermal stresses lead to brake system failures.
You can contact your customers who have had a brake rotor replacement in the last year, and have encountered an early brake rotor failure such as a cracked or separated disc brake rotor. Affinia recommends documenting the incident of any cracks in rotors, including vehicle year, make and model; component, i.e. brake rotor; date of original brake rotor replacement; and mileage at time of replacement. You also should register evidence of a defect or non-conforming product with NHTSA ODI.
A defect claim can be registered with NHTSA ODI (National Highway Traffic Safety Administration Office of Defect Investigation) directly at (888) 327-4236 or go to http://www-odi.nhtsa.dot.gov/ivoq/index.cfm and file a complaint.