Warped Front Brake Discs

Cars affected: Mainly Evo 6 & TME

Symptom:

Front discs warping which shows up as judder felt through the steering wheel and/or pedal under braking. Usually the first signs appear under high speed braking i.e. 160kph down through to 110kph.

Problem and cure:

The front discs warping on the Evo 6/TME is a well-known problem. Some cars have never warped their discs yet others seem prone to the problem. Warping can happen within a few thousand kilometers and often reoccurs when the discs are replaced, or skimmed, and in most cases it makes no difference how you treat the brakes with even careful owners eventually reporting problems. There is currently no one real reason why the discs warp. Many reasons have been suggested but it seems to be a combination of problems including lack of cooling, inferior quality disc material, too large pad size and the disc bell design amongst the candidates. As a general note though if you do suffer warped discs it is worth checking the wheel hub runout is within tolerance as there have been a few cases that the hubs have been found to be out from the factory (tolerance is ±0.001. or ±0.025mm). Unfortunately, the only definite way of curing the warping is to fit an aftermarket caliper and disc kit such as the popular AP 4 or 6-pot kit, anything else and warping may possibly reappear.

Approximate cost of repair:

AP front 4-pot brake kit - approximately 1900 euro + VAT & fitting
AP front 6-pot brake kit . approximately 2500 euro + VAT & fitting