Brake Rotors Giving Trouble? Here's What You Need to Know

How to Replace Bad Rotors: A Step-By-Step Guide

To replace worn rotors, you require access to materials such as a screwdriver, torque wrench, and brake cleaner. Moreover, to pull off a successful rotor or brake replacement, you need technical experience. 

To make your work easy, let an authorized service center or auto repair mechanic handle this complex task, which involves a thorough brake inspection and consequent repairs. 

Here’s how a mechanic would go about replacing your rotors:

1. Test drive the vehicle to check for a vibrating brake pedal that can result from warped rotors or worn brake pads.  

2. Park the car and engage the parking brake.

3. Check the brake fluid level and drain some liquid to avoid spillage when engaging the brake caliper piston.

4. Elevate the car and secure it using jack stands.

5. Remove the lug nuts, followed by the wheel (depending on whether your front or rear wheel rotors need replacement).

6. Unscrew the brake caliper bolts and take out the caliper. 

7. Keep the caliper out of the way to avoid damaging the brake hoses.

8. Check the brake line for signs of corrosion. Replace it if necessary. 

9. Detach the damaged rotor.  

10. Verify whether the brake pad set is worn and install new brake pads.  

11. Inspect and clean the rotor mounting surface using a brake cleaner.

12. Install the new rotor.

13. Fix the caliper gently without harming the brake hoses.

14. Re-install or replace the brake caliper bolts and tighten them using a torque wrench. 

15. Refill the brake fluid to the recommended level, then pump the brakes. 

16. Recheck the brake fluid reservoir and top off if needed.

17. Attach the front or rear wheel. 

18. Repeat the process for other faulty front or rear rotors. 

19. Test drive the vehicle to ensure the replacement is successful. If the pedal is firm, the mechanic will continue driving to break in the new replacement rotor and ensure smooth braking system performance.

NOTE: While modern cars have advanced disc brake systems, some economy cars may still feature drum brakes on the rear wheels. Older vehicles typically have drum brakes. These systems consist of a drum with brake shoes and pistons to facilitate braking.

How Much Does a Brake Rotor Replacement Cost?

The average cost of replacing worn brake rotors is between $310 and $470. 

This range covers the price of automotive parts, which cost around $220 to $300, and the labor rates, ranging from $90 to $170.

However, your labor costs may vary depending on whether you visit a dealership or consult an independent mechanic. 

Factors Affecting Your Cost

Some additional aspects that impact the brake rotor replacement cost include:

• Vehicle make and model: Luxury cars like the Audi A6 require costly parts and specialized labor during a brake job, unlike standard vehicles such as the Honda Civic.
• Rotor type: Different types of brake rotors, such as standard, vented, drilled, and drilled-slotted, are available in the market. Among these, drilled-slotted rotors are the most expensive.
• Auto parts quality: Original Equipment Manufacturer (OEM) rotors are pricier than aftermarket parts. However, OEM rotors last longer, making them worth the investment.
• Additional car repair: As part of the brake job, you may have to replace your brake pads along with the warped rotor. When getting a brake pad replacement, you’ll have to choose between semi-metallic and ceramic brake pads, which will determine your overall cost.

TIP: With rotor repairs, consider getting basic brake maintenance service to ensure calipers, wheel bearings, and other parts are functional. Repairing minor issues early will help reduce expenses and restore your car’s braking performance.

How Urgent Is Replacing Worn Brake Rotors?

Extremely urgent!

Worn front or rear rotors can significantly compromise the performance of your entire braking system. 

Once the system malfunctions, your car will struggle to decelerate, forcing you to press the brake pedal harder. This hard braking can strain your front or rear brake pad and caliper, wearing them out. Eventually, with new rotors, you’ll also need to book a car repair service for caliper and brake pad replacement.  

So, to avoid these costly repairs, call a professional mechanic to perform a thorough brake inspection and replace the bad rotors ASAP.   

7 Key Symptoms of Brake Rotor Wear

Here are some common signs that indicate you need a new rotor:

1. Chattering, Grinding, or Squealing Brake Noise

Rotor damage or wear can result in brake noise, especially when you press the pedal. If you hear chattering, screeching, squeaking, or squealing noises, it’s your sign to change the warped rotors. 

2. Increased Vibration and Pulsation in the Steering Wheel

Pushing the brakes should not cause vibration in the steering wheel, except for the controlled pulsation you might feel when the Anti-lock Brake System (ABS) activates.

If your steering wheel vibrates during braking, it’s likely because the brake pad material presses against a worn rotor surface. Driving with this problem can lead to poor braking performance, indicating you need a new rotor.

3. Longer Braking Distance

Disc brakes are engineered to decelerate and stop your vehicle quickly and efficiently. However, a warped rotor can lead to the failure of other parts, such as brake calipers and pads.

The result?
Your vehicle will take longer to come to a complete stop, which is especially risky in traffic or at high speeds.

To fix this brake problem, you’ll have to install a new replacement rotor.  

4. Brake Overheating

Driving your car in hilly areas may result in long downhill braking, which can overheat and deform the rotor. 

If the brake rotor wear is minimal, you can opt for rotor resurfacing (remove a thin layer of the rotor’s surface). However, if rotor damage is severe, a complete replacement is necessary.

5. Blue Color on the Brake Rotor Surface 

Blue spots on your front or rear brake rotor indicate excess braking heat. Once the blue spots appear, you can’t machine the surface. In this case, you should replace the faulty brake component for safety.

6. Reduced Rotor Thickness

Rotor thickness is usually between 10 to 30 mm. If you have had the rotor machined previously during a brake service, it’s probably too thin for reuse. You should consider replacing it to ensure safe braking and longevity.

7. Deep Grooves or Corrosion on the Brake Rotor Surface

Your brake disc can develop deep ridges and may corrode due to:

• Heat and friction generated by the rotor and pad 
• Moisture in the brake system

Corroded or warped rotors can disrupt the brake operation and should be replaced immediately.

4 Brake Rotors Replacement FAQs

Let’s have a look at the answers to some common rotor-related questions:

1. What Are the Different Types of Brake Rotors?

Brake rotors come in five types:

1. Blank and smooth rotors: These simple and affordable rotors are found in the disc brakes of most passenger vehicles, such as standard sedans.

2. Slotted rotors: These rotors have special slots on the surface. They are usually found in heavy-duty trucks and SUVs. 

3. Vented rotors: These discs have internal vents between the front and rear surfaces. These are commonly installed on the vehicle’s front axle and are ideal for daily driving or light towing.

4. Drilled rotors: These ones have a series of holes drilled in a spiraling design across the surface. Cars driven in wet climates usually have drilled rotors, as the design promotes safe braking in damp conditions.

5. Drilled and slotted rotors: These rotors have both drilled holes and slots set in spiral patterns on the surface. They’re usually used in high-performance vehicles like sports cars.

2. How Long Do Brake Rotors Last?

On average, conventional brake rotors last 50,000 to 70,000 miles or 4 to 6 years. However, the rotor’s lifespan depends on several factors, such as the type of vehicle and your driving style.

3. What Causes Brake Rotors to Warp?

Your disc brake rotor may warp due to:

• Excess heat buildup in the brake system
• Frequent hard braking and aggressive driving
• Contaminated brake fluid  
• Lack of routine brake maintenance
• Other faulty components like the brake line, caliper, pad, and ABS sensor 

4. Can You Resurface the Rotors Instead of Replacing Them? 

Yes, rotor resurfacing is possible, but only under certain conditions: 

• It should have at least .050” thickness remaining above the minimum threshold
• It shouldn’t have cracks on the surface
• It shouldn’t be heavily corroded at the edges

NOTE: You must replace severely scored or worn rotors. To ensure your brake disc stays in top condition, visit a professional mechanic for a brake repair service every six months.

5. How to Save Money on Brake Rotor Replacement Services

Here’s how you can lower the overall cost of the replacement: 

• Purchase brake parts in a bundle: Many dealerships and auto repair shops offer special discounts on new brake pads and rotors when you buy them in a bundle.
  
• Keep an eye on seasonal brake specials: Look for sales or discounts on brake repair services and OEM parts during the holiday season
  
• Buy the brake component online: Many retailers sell good-quality brake parts like rotors at competitive rates online. You can browse multiple websites, read reviews, and check the specs to ensure you purchase a compatible product that fits your rotor or brake replacement budget.
• Check the warranty coverage: Rotor repairs are sometimes covered under an extended warranty, which may help you save money on new brakes.