Sonata I45 (YF - 2011+) :: Rotors End Up With A Lot Of Rust After Rain


Dec 27, 2014

So I'm noticing after any rainfall or snowfall, really anything that causes there to be water on the road, that my brake rotors end up with a lot of rust on them. As soon as I start driving and hit the brakes, you hear the awful grinding. But after the first time the sound is heard, the rust is gone along with the sound...

I've never had that happen on any other car I've owned. The rotors don't look thin, and they definitely shouldn't be worn out after only a year anyway.

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I'm researching rust proofing, but that seems more like a preventative action than a remedy, what can I do, it really annoys me every time I look at it. I don't know why Hyundai chose such poor material inside the wheels that rusts so easily. I have compared it to other Sonatas I see on the street, mine is a lot worse.

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I took my 2010 Sonata GLS (86K miles) into the shop last Thursday for an alignment and new front brakes since the old ones were on the wear indicators and doing some squealing/squeaking on soft left turns. Got a call from the mechanic who said the rotors were also shot, so I had them replaced as well.

On my normal commute on Monday and Tuesday this week (approx 10 miles, 95% highway), I noticed that when the car was moving at 15mph or less in a straight line both front wheels were making a noticeable high-pitched squeal/squeak, which went away with increased speed and when braking. I figured it might be a break-in issue but when it hadn't improved by yesterday I made an appointment to have the car checked out by the mechanic again today.

Got the car back today and the same sound is still happening, though now it's in the 60mph range and seems to come and go regardless of wheel direction. The mechanic said he took the brakes apart, found no issues but cleaned and lubed everything as a precaution.

I'm starting to wonder if its the bearings that are shot, but the sound hasn't remained constant as I would expect with a bearing issue. All the parts used are under warranty, so the next step I have available here is to have the brakes and rotors replaced.

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Swapped them out Friday
- took caliper off
- removed pads
- took caliper bracket off
- swapped rotor
- opened bleed valve to push back piston(used a vise/c clamp combo)
- closed valve with piston under pressure
- put in new pads
- placed caliper bracket back on

I did not remove the pins, they seemed to slide fine and the remaining hardware still looks fairly new.

Took it out all was good, bedded the brakes a bit and called it a night. Come out this morning and start to head out and it's shaking like crazy now once above 40 mph. Made it back this afternoon and took the passenger side off and its not making full contact with the rotors. I've read this can be common until the pads are broken in. Driver side appears fine, pads appear to be bedding fine and nothing looks out of the ordinary, I took the caliper back off but had to open the bleed valve to get it loose enough to let go of the pads.

I've even taken the passenger side back off and reset the piston again just to make sure.

Put everything back together and take it for a spin. Truck seems worse now even at slow speeds 25-50mph. Once the brakes start getting hot from stopping the shaking goes away. When the brakes start cooling back down it comes right back.

Going to swap back the OEM rotors and retest in the morning. Will take the new ones back If that puts it back to normal I may just replace with OEM ones then. The brakes work perfect it's just the shaking that I can't seem to figure out.

Anything to check? It seems like the new rotors are warped

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- Recently had the 7.5k service done (1/30/16) and both brake occurrences happened after this
- We park in a climate-controlled garage
- Car has about ~9k miles
- wife took a video ....

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