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Hyundai ix35 2010: Rapid brake wear

When I came to replace the original set of disc brake pads on my 2010 Hyundai ix35 at 38,000 km, the Hyundai service guy told me that I also needed to replace the brake rotors because they'd worn down below the minimum serviceable thickness limit and so could not be machined. I think this is a premature and unreasonable rate of wear, and asked Hyundai to include the replacement cost under warranty. Hyundai told me that, as with disc pads, they treat rotors as "consumables", which are not covered by the warranty, and so I have to pay the full cost of their replacement. As this will be $700 to $1000, I'm not impressed that I'm now facing such costs every 35 to 40,000 km. In my view, the brake pads should take the brunt of the braking wear-and-tear, not the rotors, which should be designed to last a lot longer than one set of pads before they need re-machining, let alone replacement. Under the new Competition and Consumer Act, the rotors as supplied should be of "merchantable quality", meeting a reasonable level of expected performance and duration. The rotors should also be fit for their "intended purpose", as the more durable component of the disc pad/rotor pair. If there's a breach of either of these statutory conditions, I would be potentially eligible for a "remedy" from Hyundai, such as including the rotor replacement in the terms of the warranty, and refunding to me the costs already paid. Do you think this path of action is reasonable, and worth pursuing?

It's a course worth considering. Rapid brake wear, both pads and rotors, is not confined to Hyundai, many makes suffer from the same issue, it's a consequence of the demand for better braking efficiency. That said, I would expect rotors to last longer than that, which might give you a claim under the consumer laws. Going that way, however, will test your patience and persistence. It might be better to consult a brake specialist and fit rotors that might last longer.

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