I live in PA and every year we have to get a state inspection of our vehicles. Last April I had my 2002 Focus in and they said it needed front brake pads. At the time it had 20,400 miles on it. Fine - put the new brake pads on. It was like $250 for the pads & the inspection.

I have the car being inspected today, and they just said that the car needs front brake rotors. The car now has maybe 32,000 miles on it. I am looking at the paperwork from last year (I can't believe I kept it) and they noted that the rotors were clean and in fine shape.

What the heck. Is this normal? I know earlier models had brake problems but thought they had it figured out by the 2002 model. Am I just screwed or is there something awry here? Thanks.

 

If you wear your brake pads too much, the steel plate behind the contact material will start to get into contact with the rotor, and it will ruin it if it happens for a long enough time.

Usually you'll start hearing a wear sound from your breaks before that starts to happen, although that didn't happen on my focus, and I had to get the front discs and pads replaced this fall, although I went for a mild upgrade in the form of EBC turbogroove rotors and green stuff pads -- so I'm happy :-P