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Brakes Rusting Together After Rain

121K views 675 replies 72 participants last post by  JT Rock  
#1 ·
This discussion started in another thread but should probably be broken out separately.

Previous post: XC40 P8 deliveries delayed?

Because the XC40 Recharge (and other BEVs) use regen for a considerable amount of their braking, they don't use their brakes as often. This leads to less brake wear (good), but also allows the rotors to build up more surface rust. This isn't normally an issue but a couple of us have noticed after driving in the rain that the vehicle can have a hard time after it has been parked over night because the brakes are rusting to the pads a considerable amount (more than I've ever experienced before). This is pretty formal for all cars but there seems to be an excessive amount of it happening with the XC40s.

For the last few day's we've had quite a lot of rain and I've had this happen a few times now. This morning the brakes were very stuck, the car actually squat a good bit before it finally broke free. Once it broke free, there was an audible noise from the rear that I believe was the brake pad rubbing on a high spot from the pad and rotor rusting together. This went away after an application of hard braking and everything sounds fine now and my 20 mile commute went normally.

I'm not sure I've ever hard brakes rust that severely, especially not for sitting over night in a garage. I think this could be corrected with updated rear brake pads that are less rust prone.
 
#144 ·
I am still curious as to why this happens to you and not to me. Have you washed with the wheel cleaner I use? Did it happen still? I am brutal In getting everything set in there. I spray the junk all the way in and over the breaks and blast it with high pressure water. Getting water in it in ways it does not happen naturally.

The garage the car lives in has air flow. The air is however down town Seattle air and very polluted / oily. Even with air scrubbers going at home it gunks up computer fans. I so cannot wait to move. This polluted air might help protect?

I wonder if there is some similarity between the 3 of you (I think it is 3 now) who have this problem.

Do a you all have hone chargers that have the problem? I do not but it’s A stretch to explain it with charging. (I was wondering about the galvanic corrosion accelerated by a potential difference.

Trying to think what else would contribute.

I wonder if we could get metal blocks small. Wet them leave them in contact In your location and mine and see if they corrode the same but that has too many variables different from the P8 to be valid.

It would be a fun puzzle if it was not fing with your car.
 
#145 ·
I am still curious as to why this happens to you and not to me. Have you washed with the wheel cleaner I use? Did it happen still? I am brutal In getting everything set in there. I spray the junk all the way in and over the breaks and blast it with high pressure water. Getting water in it in ways it does not happen naturally.

The garage the car lives in has air flow. The air is however down town Seattle air and very polluted / oily. Even with air scrubbers going at home it gunks up computer fans. I so cannot wait to move. This polluted air might help protect?

I wonder if there is some similarity between the 3 of you (I think it is 3 now) who have this problem.

Do a you all have hone chargers that have the problem? I do not but it’s A stretch to explain it with charging. (I was wondering about the galvanic corrosion accelerated by a potential difference.

Trying to think what else would contribute.

I wonder if we could get metal blocks small. Wet them leave them in contact In your location and mine and see if they corrode the same but that has too many variables different from the P8 to be valid.

It would be a fun puzzle if it was not fing with your car.

I do not apply wheel cleaner to the brakes/rotors, I only do outside of wheel and fire. I clean the outside of the wheel/tire and the the part of the rim that the brush can reach. I was using Mother's wheel cleaner, but switch to Meguair's and also picked up Turtle Wax wheel cleaner. I used to use Mr. Pink to wash the car and switched their the Hydro Suds. My guess is when I pull the car in the garage after washing there is water on rotors and pads, parking brake engages and traps water between pads and rotor, the rest is history. I have washed over 2 dozen cars this way for 30 years since I am in this house never an issue.
 
#146 ·
My neighbor with 2019 model 3 told me that his breaks are grinding after the car has been parked. It is more if it was raining. He was never concerned. Grinding goes he said after some driving. He uses one pedal driving.
It is possible that Volvo genuine break pads that are made in India (believe they still use them) to have some bad batches. Who knows. It is super frustrating.
 
#150 ·
My neighbor with 2019 model 3 told me that his breaks are grinding after the car has been parked. It is more if it was raining. He was never concerned. Grinding goes he said after some driving. He uses one pedal driving.
It is possible that Volvo genuine break pads that are made in India (believe they still use them) to have some bad batches. Who knows. It is super frustrating.

All my cars have had some minor oxidation after being parked and on occasion you would hear that grind off when backing out of the garage. None have seized together and made loud clunk then loose pieces of the pad material.
 
#147 ·
Oops I spray the Meguair's all over tire wheel and inside in the breaks area. I thought that’s what the directions said which I probably miss read. I thought it was helping remove the metal particles all up in the break system. It goes a nice pink color on the discs :)

Now I have to go look up the directions. Then again mine is not sticking so maybe this broken clock is having one of its two correct times a day :)

mans yes it must be frustrating as ….

I do not believe it is random. There is something going on ….
 
#148 ·
Maybe I need to get it all up in the pads rotors to get rid of what ever it there, at this point I don't see this going on much long. Working on trip/attempt 3 for this. Only 1850 miles on the darn car.
 
#149 ·
Could be the spray + water blasting removes buildup. I thought it said that on the bottle. Worth a try :)

I am full on nursing anal when I rinse them. No trace of the chemicals are allowed to remain
 
#152 ·
I get it, I had ceramic coat put on the car, wash it frequently, even blow dry wheels and tires (as well as car now). If this were a beater car that I was going to have 3 years on a lease I would care less, but I bought it expecting 6-8 years of use. I will be lick if it makes it 6-8 months.
 
#151 ·
Do not spray the breaks with metal particles removal spray. Actually do not spray the breaks with anything. It is altering the surface metal composition and that can create hot spots and warp the disks. I have Akebono ceramic pads on both XC90s and these are so far were the best I ever had. When the break pads and disks heat up a layer of the material of the pads will deposit on the break disks and will create more frictions and very little to no rust and virtualy no break dust. Cars will sit inside the garage for 3-5 days and there will be no rust on the disks. However once I wash the car the detergents will make spots which will rust and breaks will grind a little. I wish my car to be with these type of breaks. Anyway, will see October 15th. So far this is the ETA for mine and adventure begins.
 
#153 ·
I had Akebono ceramics on my Audi an they were great, also had EBC red stuff, also very good. Unfortunately they do not make pads for the P8, only EBC has their organic, not sure I want 2.5 ton car being slowed by organic brakes.
 
#154 ·
#155 ·
That is not metal particles remove spray, it is just wheel cleaner. It should be fine, but do spray it on the wheels. Lots of the spray will end up on the breaks but that is OK. Do not let it dry and rinse well. I am using something similar to clean my wheels and no problems.
 
#156 ·
I assumed active brake dust removing agents that turn purple was removing the metal particles as break dust is metal dust.

Is metal particle removing spray a specific product type?
 
#157 · (Edited)
Yes it will specifically say that and it is not for breaks at all. It is for paint to remove microscopic embedded metal particles. It is acid designed to not react with clear coats. Still super careful with that stuff because can make permanent stains on clear coats. Break dust is strong carcinogen. Always wet the dust before removal and do not wipe it with your finger or with dry cloth. Use gloves always when working on the breaks and mask if there is no proper ventilation.
Meguiars Iron Decon KIt
 
#161 ·
Probably need to talk to the lemon law layer to make sure this does not impact possible lemon law case. Wife is frustrated as she was planning on taking my car in 18 months as hers and I buy something else.
 
#162 ·
What other problems beside the break issue did you have? My XC90 when brand new had rear hub bearing replaced and later the axle on the same wheel. There was something else and that was it. At 100k miles seized the water pump (never ever pressure wash the engine bay...any bay actually) which was my fault for pressure washing engine few times. I did my front suspension last year. The car is currently at 160k miles. No problems.
My point is - yes be frustrated it is understandable, but keep in mind that once you solve this problems and the car settle you should be fine for a very long time. That is my life experience with 850, XC70 and XC90s. However there is one very annoying thing with Volvo. The cars are very specific and if generic mechanics start touching they will mess the things up 100%. It is far away (thank God) from civics, cr-vs and camries. It is hard to find good Volvo mechanic. Do not let me start on stories it will be very very long post.
 
#163 ·
The IHU gets hosed up occasionally, get unresponsive and refuses to follow commands. Actually if we can get the brakes resolved I love the car. We have 2 XC40s, a T5 and P8. I would dare say if I could gain my confidence back a C40 or another P8 would be in our future. The only 2 EVs that look appealing are the Lyric (who knows when and loaded the price tag is likely $70K+) and the Genesis GV60 (concerned it will be too low to the ground and may also be up around $70K+). I have never been so conflicted about a car before, such a love hate relationship. We went to DR appt today 36 miles round trip a little highway 55mph and the trip got 30 kWh/100 miles.
 
#164 ·
Just wait for now. Volvo is like that. Sometimes when somebody asked me how easy is to fix Volvo I will always answer: it is very easy, you need good hands and lots of swearing. That said my 850 went to 350k miles before scarping and it was still running. The other 2006 XC90 that we are going to sacrifice in the name of the electric almighty has nearly 200k miles. Bought second hand. Fixed it and it goes 6 years with few minor issues. But it is old car and has some temperament.
 
#165 ·
I am done. IHU went nuts again today. Bluetooth was toggling itself on and off, it was not taking to internet. Google assistant would not respond. The maps on the instrument cluster blanked out then came partially back. Then it would dump calls in flight and then never respond to any commands. Told the dealer I will not accept anything but Volvo brake parts and they can troubleshoot the IHU again. I am pretty sure this is the August update being a joke. I will go through the motions now to run out their clock and told the the lemon lawyer I will be reaching out in a few weeks as soon as either the attempts or days threshold is met. Hopefully having all the videos, pictures and then work orders for repairs will make a lemon law but back straight forward.






I can’t wait to see how Volvo handles soccer moms with 22 XC60s with all the bugs.
 
#166 ·
This is BS. Nothing but trouble. Do the right thing, it is the best you can do. At least you know what is going to happen next. Keep filming and keep records of everything, even your phone calls with the dealer if you can.
So far some of the cars seems to have IHU troubles, AC troubles and grinding breaks troubles. Silver lining - at least everything is shown within first 2-6 months of ownership.
 
#168 · (Edited)
Honestly, reading all these IHU issues I am starting to think that is more software related than hardware. Who knows...

Perhaps do the old Volvo trick, disconnect the 12V battery overnight. Works sometimes. The other thing I am thinking is that the 12V battery Volvo installed is not powerful enough or it is not charging properly. It seems with all this lagging that is happening is like power-safe mode. It is similar to my phone. Just guessing here. Sorry, can not offer any comfort...
 
#169 ·
Honestly, reading all these IHU issues I am starting to think that is more software related than hardware. Who knows...
Probably, but goes to show how premature this system is. I was solid until August update. We can argue about picking Google OS as a good or bad thing, but Sensus was solid. To start rolling this to mainstream models XC60 is going to flood dealers with issues. I don’t care how much fun this car is to drive this is just not acceptable any more. When on any given day I need to wr]Rory about if I park the car with wet brakes if my brakes will seize or grind, or will the infotainment system crash and burn in the middle of usage.
 
#172 ·
He Keith

(Joke)Do you live in the evening Bermuda Triangle?

I am sorry you have had the worst luck of anyone on the board. I get the music to Christine (bad to the bone playing) with images of your car crushing people in production then being delivered. Towed. And on and on ….

Hands he Keith the award for worst Volvo ev luck :( a dubious award indeed :(
 
#173 ·
I don’t think I have had worse lo]idk that others, I am just the most vocal of every issue. By far the most trouble I have ever had with a car. Has me hesitant on another EV. Next EV will be a lease as I am not betting on any of them.
 
#175 ·
They clearly don’t test this software well. I wonder if they can downgrade to the previous release? If so I am thinking they need to factory reset to do so.
 
#176 ·
My breaks wheels were grinding a bit today so I did the P button break clean. Alas it was a vertigo day so the breaking was not pleasant. Made me think how silly it is to have to undergo maximum deceleration to clean them.

I wonder how mad a Volvo driver I must look max deceling …

I want a button that switches off regenerative breaking for 30 seconds. Then I can gentle clean the breaks off.

As for the software I wonder how many hardware combinations there are to test for. And as each test bed would have to be a whole car …

Can you imagine if there were 10 options for each component … each with driver software … couple easily become very hard to test … for them … and maybe this would lead to consumer testers.