NHTSA Complaint #10269322 — 2005 FORD FOCUS

THE INNER BRAKE PADS ON THE FRONT AXLES ARE PRONE TO BINDING DUE TO RUST. THE CLEARANCES ARE VERY TIGHT. THIS CAUSES PREMATURE, UNEVEN BRAKE AND ROTOR WEAR ONCE THE PAD RUSTS UP AND STOPS FLOATING. MY PADS JUST FAILED AFTER 42K MILES; YET THE OUTER PADS WERE OVER 1/4" THICK. I PROPOSE A SEVERAL-PART REMEDY (FIRST 3 TO BE DONE BY SERVICING TECHNICIAN): 1. EXAMINE THE PADS MORE FREQUENTLY THAN THE USUAL ONCE A YEAR REQUIRED BY TYPICAL SAFETY INSPECTIONS; PULL THE WHEELS AND CHECK FOR MOVEMENT OF THE INBOARD PADS. THE PADS MAY HAVE TO BE RETRACTED WITH A C CLAMP SO THEY HAVE ROOM TO MOVE. 2. IF THE PADS ARE FROZEN, REMOVE BRAKE DISK AND PADS AND REMOVE RUST ON THE SLIDING SURFACE DOWN TO BARE METAL WITH A FLAT FILE, UNTIL PADS SLIDE FREELY. 3. LUBRICATE SURFACES WITH MOLYKOTE OR SIMILAR ANTI-SEIZE COMPOUND. 4. THE MANUFACTURER SHOULD REVIEW THE DESIGN WITH BRAKE VENDORS TO COME UP WITH A SOLUTION WHICH COULD BE INCORPORATED INTO REPLACEMENT PADS. IF SLIGHTLY SHORTER PADS ARE THE ANSWER, THEY SHOULD INCLUDE ANTI-RATTLE MEASURES. ALSO, A SQUEALER SPRING SHOULD BE ADDED TO CONTACT THE BRAKE DISK WHEN THE PAD IS ALMOST GONE TO GIVE AN AUDIBLE WARNING TO THE DRIVER. THESE WORK WELL ON CHRYSLERS (I DON'T KNOW WHO MAKES THEM). *TR