I recall many noting that components of our brake assemblies, as seen through the wheels, commonly rusts. I wouldn't expect this is a serious issue in terms of brake performance/safety, but it's unsightly and conjures images of cheap construction, in my opinion.

I've noted in the FAQs a Mazda TSB, MT000003559 - RUST ON BRAKE ROTOR HUBS, and wanted to ask if anyone out there has taken this issue to their dealer for service. If indeed there is a way to prevent this rust from coming back and it's a free service under warranty, I'd just assume get it done, but have a feeling with something cosmetic like this it will be difficult to get the dealer to do it.

Secondly, I too have noted the clutch chatter issue as listed in Mazda TSB, MT000003848 - CLUTCH CHATTER DURING COLD TAKEOFF, and wanted to ask how many of you have asked for this service and whether you had any problems getting the dealer to do it.

I'm aware this issue has been spoken of before-- It's not whether others are having this problem that I'm researching-- I'm interested in leaning about how many of you have had problems getting the dealer to fix these documented issues.

Thanks, all!

 

i complained about the rusty rotor hubs to a toronto dealer last week. the dealer had never heard of the TSB. when i showed it to him, he said he'd contact mazda canada. the mazda canada rep for that dealership is not available in january, so i've been told i'll get my answer in february.

 

I have been noticing that brake rust myself. It is getting quite bad on my car. I too, live in Toronto. I was very disappointed when it started to appear. Any resolutions so far?

 

I have also noticed rust on the rotors and hubs, but I havent done anything about it yet. I am planning to this weekend and will let you know the result. I have also noticed a grinding when braking after noticing the rust.

 

The rust is NORMAL and unavoidable. It has absolutely nothing to do with "cheap construction". Brake rotors are steel, and since steel contains iron, they rust. Other than very expensive ceramic or carbon-composite rotors, ALL rotors are made of steel and ALL rotors show rust. Any surface rust that is on the braking surface is scrubbed off the first time you hit your brakes in the morning. And the rust that is on the hubs and edges of the rotor cannot be stopped.

The only way to deal with it is to scrub it off, or MAYBE you could get it real clean and use a clear-coat of some sort on the hubs and edges, but I doubt even that will stop it.

I think it is very noticeable on the Pros because the rim design leaves a lot of the hub and rotor visible. But next time you are in a parking lot, go look at some other cars - I'd bet 9 out of 10 have similar rust on the rotors. Go look at brand new cars on a dealer lot - they'll have slight rust, too.

Seriously - if you complain to the dealer about this, they have every right to laugh you out of the building.

~HH

 

I believe dealers *don't* have the right to laugh at anyone. If such concerns were not being taken seriously by Mazda, they wouldn't have issued a TSB on it now, would they? I think not.

I wouldn't deny that the construction of the brake hubs, given their steel composition, are prone to rusting-- Indeed it does happen. What I said was it conjures up images of cheap construction, as I've never noted rust as easily visible on other cars. That doesn't mean it IS cheap (indeed, when they're not defective in the first place like mine were, the Protege's brakes are considerably BETTER than other competitors), it just LOOKS cheap.

The TSB issued by Mazda suggests that dealers are prepared to fix the problem; even replace the hub if the customer isn't satisfied. Please read the bulletin. That's what it says. I'm not arguing against you, but the bulletin suggests that it IS possible to eliminate the problem, contrary to what you're saying.

Anyway, it isn't the biggest deal-- I already acknowledged that this is a cosmetic issue. I just wouldn't mind if it didn't happen anymore, that's all I'm saying, and if dealers will fix it, great.

 

my co-workers RSX gets way worse break rust then my pro5 even his calapers are rusted

 

Hmmm... Mazda probably got threatened with lawsuits... issued a TSB to shut them up... spend more money on frivolous cosmetic issues to "repair" a non-problem... raise prices on new vehicles and parts to cover the costs...

Gee, thanks...

You know, my antenna is not as shiny and smooth as it was when it was new. Mazda really should have chrome-plated it... you think if I whine enough I can get it fixed?

 

but then your shiny chrome-plated antenna would just start to chip eventually, and you'd have to whine again.

 

But... if the rest of you join me, maybe we can get the base price of the Protege up to $30k!

 

Okay, now that I have read the TSB, I find this more ridiculous than before.

First off, the TSB is merely telling dealers to fix a "problem" that doesn't even exist. Rust on rotors is part of life. But now Mazda decides they will FIX it? What's next? Will they "fix" my shitty paint? My chipped fog light? Okay - how about the fact that some of the undercar parts are also rusted - if I bitch enough, can I get those painted, and eventually REPLACED?

This is nuts. Not only is it frivolous complaining about a normal part of owning a car, the "fix" is the dumbest thing I've ever read. All they say is "sand", use "primer" and "heat-type silver paint". WHAT?!?!? This TSB is insane. WHAT primer? WHAT paint? Are dealers simply supposed to use whatever they feel is going to work?

I can't believe Mazda would actually issue a TSB about this nonesense, and furthermore give generic instructions on how to "fix" it. The paint WILL flake off. The rotors WILL rust again. Maybe they are just trying to hold people off until the warranty is up. But how do they propose to take care of the rusty outside edges of the rotors? And if they are replaced, they will rust again in a matter of weeks.

Shame, really - some poor dealership is now dealing with a guy who comes in once a month to have his rusty rotors replaced for free - all because Mazda issues a dumbass TSB about something that is a normal wear-and-tear type thing. If I owned a dealership, I'd do everything in my power to refuse this type of repair. It's a waste of time and money. And as a Mazda owner, I would be furious to learn that my car had to stay in the shop an extra day because someone was in there getting their damn rotors painted.

Expect long lines for service at your local dealer while everyone with a little rust spot goes in for a sanding.

~HH

 

I see what you're saying, hihoslva.

This, quite true, is just a cosmetic issue and one that happens to all vehicles-- I just would love it if there was a long lasting way to prevent it. And I still believe this issue is more visible on the Protege than most other cars I've seen.

I also expect that indeed this posted fix from Mazda is temporary. Paint does chip, etc., and, like many repairs I'm sure, is just a way to keep people quiet until the warranty runs out, if that's the intention.

The other question I'd have, on this note, is whether Mazda issuing a TSB means it's a documented warranty repair, or are they simply posting instructions on how to fix any kind of problem? In other words, is this the kind of repair that the dealership would charge you for, or is it a free warranty service? (Which is independent of whether it's frivolous or not)

Lastly, anyone know about any kind of clear coat/rust preventative treatment we could apply ourselves? Whether it's normal or not, I'd still rather it not happen at all, and if there's a simple treatment we can carefully apply ourselves to prevent the rust, why not go for it? Sand off the rust, rinse, dry, apply the treatment, and repeat as the need presents itself. Seems to me that guys who, for instance, show their cars at meets and the like routinely clean their brake rust and/or have a method for preventing it...

And oh yeah, this tread also deals with the clutch chatter issue, which is certainly NOT normal.

 

As far as a DIY thing, I'd say the absloute best treatment would be a thorough cleaning/scrubbing to remove all rust, then an application of brake caliper paint. I suppose you could use high-temp spray paint like some guys do on the calipers, but I think the real stuff is better; it's a two-part epoxy that is applied with a foam brush - it's thick, and it works well. It does come in silver, too - so you don't have to have red or blue hubs (yuck). A good application of that stuff ought to last for a good oong time, and will prevent future rusting.

The clutch chatter IS a legitimate issue, and one that has been widely addressed on this forum. You should absolutely be able to get it repaired under warranty.

~HH

 

The customer is always right! Do all manufacturers have TSB's to avoid lawsuits for rusty rotors? Nope. This weekend I will be bitching about the clutch chatter, engine rattle at 2800RPM and the rust on my rotors and hubs. Dont get me wrong, I love my P5 and Im glad I bought it. But tweaking things to optimal satisfaction should be every persons goal.

 

Have fun getting your rotors painted. Just don't file a lawsuit when your car slams into something because your pads clamped down on paint rather than bare steel like they were designed. But hey, at least they were pretty...