RE: Need really good rotors.
Red Box Rebel '
1. When Ford engineered its front rotors for the Mark VIII, Cougar, and T-Bird, they accepted the design with the least amount of mass. (Weight) Corporate Average Fuel Economy standards mandated by the Federal Government was the driving force.
2. Ford began having a lot of complaints about front brake shudder in the early 1990's. Ford published several Technical Service Bulletins (TSBs) on the subject. One of the reccomended treatments was the "on the car brake lathe" as a way of machining the rotor's dual plains as it rotated on the vehicle's spindles.
3. Since the early 1990's, brake pad materials have progressed. Whether that means they have gotten better is debateable. However, choosing between semi-metalic, organic, and/or ceramic will provide different performance and different dusting problems. The type of pad you choose will generate different amounts of heat and will have different wear characteristics on the rotor.
4. All but a couple of the replies I have read have failed to mention doing a complete brake analysis. All four wheels perform braking functions, therefore, you must take a four wheel approach when performing preventive and corrective brake maintenance.
5. Inspect the calipers. Ensure that the pistons are not binding and make sure the slides are properly lubricated with silicone brake lubticant.
6. Are the rear brakes pulling their own weight? You know, are they performing their fair share of the braking? If not, too much of the braking will fall to the front brakes. Premature wear out and warping can be the result.
7. Machine all four rotors at the same time, replace all four sets of pads at the same time, and make sure all four calipers are properly functioning at the same time. This is a basic start to eliminating your problem.
8. If you did all that when replacing your brakes the first time, then there is something else wrong. Driving habits can contribute. However, other worn parts can contribute as well.
9. Are the front hubs ok? Are the upper and lower control arm assemblies ok? Are the wheel and tires propery balanced? Are you able to keep it below 80 mph part of the time?
