Most drivers first notice brake wear because something doesn’t feel right. Maybe the car shakes when you brake, maybe there’s a noise coming from your brakes like a high-pitched screeching sound, or maybe the brake warning light on the dashboard is gently babbling at you. These are classic brake pad wear symptoms. And once you’re in a shop, the next logical question arises: if the brake pads need replacing, do the rotors automatically need it too?
The brake rotor (also called the disc in disc brakes) is the round piece of metal that is mounted on the wheel hub. When the driver applies the brakes, the caliper pushes the brake pads onto the rotors, reducing friction and bringing the car to a stop. Some shops recommend replacing both at the same time because they both wear out over time. But unless the rotor is worn, the brake pads and rotors don’t necessarily need to be replaced at the same time.
Brake discs should be replaced if they are warped (implied by pulsating sensations during braking), deeply cut or below minimum thickness. But the brake pads can wear out before the rotor. The thickness of the rotor must be within the manufacturer’s disposable specifications to dissipate heat safely, which can happen even if the brake pad is worn. By measuring the rotors to make sure they are still a safe thickness and checking that information against your owner’s manual, you can save some money by waiting to replace them.
Reapply or replace, which is better?
As previously mentioned, some situations require rotor replacement. If you already notice deep gouges, surface cracks, overheating or “bluing”, or rotors that are smaller than their throw-away thickness, it is best to replace the rotors immediately. Brake discs usually last quite a long time (between 55,000 and 130,000 kilometers with normal use), but once metal becomes too thin, it can no longer dissipate heat properly.
However, if the rotors still have sufficient thickness, resurfacing becomes an option. Essentially, it is a process of working a thin layer of metal from the surface to restore the flatness of a warped rotor. Resurfacing is only possible if the rotor has sufficient material left, without defects such as major warps or cracks. Resurfacing was common especially in the past, but many modern cars often have relatively thin rotors from the factory, leaving little room for resurfacing. As a result, some experts no longer recommend it, but it can still save you money in the right situations. Depending on the type of vehicle you own, Repair Pal estimates that replacing the rotor will cost between $559 and $730. Resurfacing, where still offered, can sometimes be as cheap as $15 to $40 per rotor (if you’ve removed the rotor yourself, that is).
So what’s better? Replacement gives you full thickness, renewed brake rotor life and no more glass brakes. Refitting is cheaper, but only worth it if the rotors are still thick and undamaged. You don’t have to replace the rotors every time you replace the brake pads. But if your rotors are beyond salvage, replacing them is a pretty good solution.
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