NHTSA Complaint #11624685 — 2022 VOLKSWAGEN PASSAT

In May of 2023, I reported that the driver side rear brake caliper appeared to be sticking as one pad at that corner was completely worn down and making contact with the rotor, while the other pad at that same corner had no visible wear. Dealer replaced the rear left rotor under warranty (40,805 miles). Warranty also covered both rear rotors and rear pads due to rotor damage. In February of 2024, dealer inspection noticed the exact same issue on rear right brake caliper and replaced it under the extended warranty (59,631 miles). Although rear right rotor was damaged again, the extended warranty did NOT cover rear rotors or pads and I had to cover the cost out of pocket. In November of 2024 with approximately 80,000 miles, I performed a full brake inspection and noticed that even at this mileage, there was NO visible wear to the factory installed front brake pads (which at this mileage was odd and concerning), and while inspecting the rear pads I noticed that there was no visible wear to the rear left pads, but the rear right pads were worn down almost to the rotor. This uneven wear was shown to the dealer and after a day of "diagnosis", the dealer tech found no issues. They claimed fluid was flowing freely and the brake pistons were not sticking (pointing to the ABS module applying significantly more braking force to the rear right corner, in my opinion). I pressed the issue and after another day of diagnosis, they claimed the ABS module was defective and submitted the claim to the extended warranty. Claim was approved and part is no order, but I do not trust the braking system on this car with brake pads wearing unevenly down to the rotors every 20,000 miles and no perceivable braking force taking place on the front brakes. I, again will have to cover the costs to replace the rear pads and rotors due to continued related and warrantied part failures. I also raised the issue to VW Customer CARE, who created a case and is investigating with the dealer.