2006 Sonata rear rotor rusting and pitting

Discussion in 'Hyundai Sonata' started by Voyager, Oct 20, 2008.

  1. Voyager

    Voyager Guest

    I just did my 40,000 mile maintenance and inspection and while rotating
    the tires inspected the brakes. The good news is that that pads appear
    to be less than half worn out. Yes, after 40,000 miles there is a lot
    of material left. The bad news is that the rear rotors are rusted and
    pitted pretty badly. I noticed they were noisey a few times this summer
    when I didn't drive the car for a week or so as I was riding my
    motorcycle so much. I was amazed though when I looked at the rotors
    tonight as they are in bad shape. At this point, I'm just going to run
    them until they finish off the rear pads, which looks like it may take a
    while even with the pitting, but the certainly will need to be replaced
    when the pads are replaced.

    I've never seen a vehicle with rotors that pitted this badly other than
    old vehicles at a junk yard that have sat for for YEARS. Has anyone
    else had this problem with their Sonata? I wonder if anyone makes
    stainless rotors for the Sonata. The stock rotors appear to be very
    cheap cast iron, I'm guessing recycled iron. This reminds me of the
    problem Ford had in the early 70s when they had a lot of body
    rust-through problems which, IIRC, were blamed on recycled steel that
    hadn't quite been recycled enough and had impurities throughout the
    metal that caused rust to commence.

    Matt
     
    Voyager, Oct 20, 2008
    #1
  2. Voyager

    jim Guest

    Is this not still under warranty?

    Jim
     
    jim, Oct 20, 2008
    #2
  3. Voyager

    Voyager Guest

    I figured not as most brake related items are brushed off as "wear
    items", but it probably is worth asking. The care is past the 36,000
    mile point though so I suspect it is in just the "power train" part of
    the warranty now.

    Matt
     
    Voyager, Oct 20, 2008
    #3
  4. Voyager

    631grant Guest

    If the car sits for just a couple of days, the rotors will show some rust,
    but I don't know about the pitting, unless the castings were bad and had
    porosity, which would (or should, depending on your stealership) be covered
    as defective.
     
    631grant, Oct 20, 2008
    #4
  5. Voyager

    Ed Pawlowski Guest

    I've found that my Sonata rotors will rust in as little as 12 hours in damp
    weather while my Buick rotors never show signs of rust even after a couple
    of weeks sitting in the driveway inches from the lawn. . Must be a
    different alloy?
     
    Ed Pawlowski, Oct 20, 2008
    #5
  6. Voyager

    Voyager Guest

    Yes, all cars do that. My Chevy and Chryslers get a thin uniform layer
    of surface rust that comes right off at the first use. The Sonata makes
    a loud grinding noise for several stops if it sets more than a day or
    two. The pitting is worse than anything I've seen on a car. The only
    car even close was an 84 Accord I owned whose rotors rusted beyond
    service in less than 60K miles. By way of contrast, the rotors on my
    1994 Chevy are original and have 106K and 15 years on them.

    Looks like Hyundai and Honda buy their rotors from the same source.

    Matt
     
    Voyager, Oct 20, 2008
    #6
  7. Voyager

    Voyager Guest

    Yes, I'm seeing much the same comparing my Sonata to my Chevy truck and
    Chrysler van. Something is obviously inferior about the Sonata rotors,
    but I don't know what it is. I'm guessing you are correct though in
    that it is a different composition or they are using recycled steel that
    has impurities in it that is accelerating the rusting and pitting.
    These rotors are complete trash in 40K miles and the pads aren't even
    half worn out near as I can tell visually. That is simply unacceptable
    to me.

    Matt
     
    Voyager, Oct 20, 2008
    #7
  8. Voyager

    hyundaitech Guest

    This isn't uncommon, Matt. I see it mostly on cars that are drive
    infrequently or for short trips, even though you don't seem to fall int
    that category.

    I, too, think it's a problem with the metal in the rotors. Rotors ar
    covered for 5 years/60k miles, but the warranty pamphlet specifically say
    rust is "not covered."

    Can't hurt to ask the dealer, though. Many managers/advisors neve
    actually read the pamphlet. You may wish to specifically ask for th
    person who knew something about the "fuel tank air filter." I imagin
    you'd be rather upset if someone told you it was covered, and you the
    made a significant outing only do find out it wasn't
     
    hyundaitech, Oct 20, 2008
    #8
  9. Voyager

    Voyager Guest

    I have driven the Sonata infrequently a few times this summer as the
    weather was good and the K1200LT was calling... :)

    I don't think I ever went more than 6 days idle though as I drive the
    Sonata to church each Sunday at a minimum. And no comments about Sunday
    drivers!!

    I figured as much as I've not see rust ever covered before.

    Yes, it can't hurt to give them a call.

    Matt
     
    Voyager, Oct 21, 2008
    #9
  10. Voyager

    John Guest

    Wonder if it was a bad "batch". I,ve had 3 Sonata,s over 11 years, the
    latest for 5 yrs, 80,000 km and no pitting whatsoever on any of them. As
    you say, worth harrasing the dealers.
    John
     
    John, Oct 21, 2008
    #10
  11. Voyager

    hyundaitech Guest

    I don't think so. I've been seeing this for about 5 to 6 years or so
     
    hyundaitech, Oct 22, 2008
    #11
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