Brake Disc Corrosion

[Sunil]

When I was dropping off my C2S for its first service today, I pointed out a slight shudder through the steering under braking. The OPC called me later in the day to confirm that the brake discs, front and back, had suffered from severe corrosion and required replacement at a cost of £1,646.55. Apparently this is very common.

The car is not quite 2 years old and has only been driven 15k miles. This is not 'wear and tear' (not in my book anyway) but it's not covered by the warranty. Ironically, the wheel bolts were replaced under the corrosion warranty which I think is a bit 'nuts' in light of the situation with the discs.

The OPC are doing their best to look after me and will speak to Porsche GB about it tomorrow but, to be honest, after the TMC debacle, I don't expect much as Porsche GB are quite happy to leave the OPC high and dry.

Needless to say, I was very disappointed as I drove away from the OPC today but loved every minute of driving my car after getting out of my BMW 318 estate courtesy car! I still have £10k with the OPC from my cancelled TT order and had decided to either get a GT3 in September or an X51 direct injection facelifted C2S at the end of the year, if it's available. Life was looking good and I honestly expected to be in 911s for the next 10-15 years as nothing gets close to it for what I want from an everyday car. I'm now reconsidering my next purchase depending on how Porsche GB handle this.

Am I being naive here? Surely Porsche can't expect you to keep and drive the car in environmentally controlled surroundings? Does anyone have any experience of the same?

 

[THX911]

If the car is left un-driven for prolong periods after a rainy/wet day drive then corrosion can start building up very easily. I have been told that a non heated or a not fully insulated garage is worse than leaving it outside as when it is out the wind and air movement disperses the moisture faster. Also another common cause is leaving the car un-driven after a wash...

If you are concerned about the OPC price then get it done at an Indi; if the corrosion is not too bad (inside of the disc is always worse than what you see on the outside) then you can get them skimmed.

Finally, I would say get a second opinion at an Indi as OPC saying they need replacing may be fixed by simply doing some heavy breaking from really high speeds...

 

[Rotorhead]

ORIGINAL: THX911

If the car is left un-driven for prolong periods after a rainy/wet day drive then corrosion can start building up very easily. I have been told that a non heated or fully insulated garage is worse than leaving it outside as when it is out the wind and air movement disperses the moisture faster. Also another common cause is leaving the car un-driven after a wash...

If you are concerned about the OPC price then get it done at an Indi; if the corrosion is not too bad (inside of the disc is always worse than what you see on the outside) then you can get them skimmed.

Finally, I would say get a second opinion at an Indi as OPC saying they need replacing may be fixed by simply doing some heavy breaking from really high speeds...

That's an accurate summary.

It is, I believe, covered in the Driver's Manual, and is not covered under warranty. However, at 15k miles the discs should still be skimmable - for c.£100 each.

 

[garyw]

As the guys have said above, remove it from the dealers and go see an indi.
The OPC are doing the usual diagnostic by replacement issue.

With my 996 (same issues) the car was left open to the element and the discs lasted 26K.
Everytime I got in it the discs sounded terrible due to the corrosion but after a few sharp braking operations it cleared up.
A skim might solve the issue, but news discs will probably be alot easier on the wallet from an indi.

garyw

 

[Rodney Naghar]

but news discs will probably be alot easier on the wallet from an indi.

I agree.
On Eurocarparts they are £128.65 each for the Genuine items or £86 for OEM.

 

[bobfair]

I had exactly the same problem with a previous 911. Porsche discs are very susceptible to rusting. If you use the car in winter on salted roads then it is a good idea to wash the disc completely with a hose (the 996 handbook said you had to do that regularly) and then drive the car to dry them off. You need to drive the car every time you wash it if you want to keep the discs in good condition which can be annoying. Problem not so bad if car used every day.
I had a big row with PGB and had my discs skimmed but that made them very rough with lots of vibration through the pedal. Eventually my OPC replaced them which was the right thing to do as I went on to buy 2 more 911's so I am sure they have more than got their money back.
Rapidly rusting steel discs was one of the reasons I went for the PCCB's on the Turbo

 

[garyw]

ORIGINAL: bobfair
Rapidly rusting steel discs was one of the reasons I went for the PCCB's on the Turbo

[] Thats was one of my main considerations also, that and I was into Yellow at the time..
However I fell at the final hurdle and stuck with Red and the funds for quite a few sets of discs []

garyw

 

[okellyt]

Adrian

similar problems with my first boxstre. None so far with the second mainly because I came to the smae conclusion as you - Drive it every day or do a few high speed stops on an empty road, worked for me an I got nearly 40k out of both sets of breaks!

 

[garyw]

ORIGINAL: okellyt
I got nearly 40k out of both sets of breaks!

Wuss......[]

 

[okellyt]

ORIGINAL: garyw


Wuss......[]

What can I say I am a smooth driver[8|][8|][8|] honest guv - Ok a wuss

Doubt the 997's will last anywhere near as long.........

 

[Sunil]

Thanks for all the input. I'm waiting for Porsche GB to get back to me to tell me what they're going to do about the discs. I suspect they'll do nothing in which case I'm having the discs replaced at a cost of £545 plus labour by an independent. Needless to say, I'll replace the pads as well. I'll update the thread when I'm further forward.

On another note, I started thinking about PCCBs on my next car but was advised againt it because of the replacement cost.

Thanks again to everyone who posted.

 

[Rotorhead]

I'd be surprised if Porsche do contribute, but you never know.

Are you sure they can't be skimmed?.

PCCBs have a number of benefits and may well be worth considering in the future, particularly if the long life claims live up to expectations and the costs can be reduced.

 

[jr2015]

Hey Sunil,
Drive it more and wash it less!That`s what its for.
I bet your tyres are as good as new.
regards,
jr.

 

[Sunil]

ORIGINAL: jr

Hey Sunil,
Drive it more and wash it less!That`s what its for.
I bet your tyres are as good as new.
regards,
jr.

I try to drive it as much as I can but I'm away regularly and that's probably what's caused the problem. I've only washed it twice in two years. I realised early on that, for as perfect as I try to get it, 4 hours of my time is too valuable (not to mention too much hard work) so it only ever gets washed at a Porsche approved bodyshop as I don't trust anyone else. I should get them to stamp a card everytime they wash it for a full Porsche approved washing history! []

So far as tyres go, I'm 3,000 miles into my second set - don't fret, I enjoy enjoying my car! []

 

[jr2015]

well said, I like the washing history idea!
jr

 

[peterfrost]

I had very good results from Autofarm-a skim and new pads about £180 for front axle I think-Can't recommend them enough-real enthusiasts.
As good as new.