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Hi guys, I was reading a thread a little while ago (sorry , forgot who's thread) that said that it is possible to warp a brake rotor by overtorquing the lug nuts. Is this true? If it is, will loosening the lug nuts and re-tightening them fix the problem? I have a '95 shortie sport 3.0 that chatters when I hit the brakes. The tires were replaced about 2 months ago by a Canadian Tire shop.
If the rotors are warped the only fix is to either machine them or to replace them, the main problem in my experience is not only over torque but uneven torque. They probably used torque sticks at your tire shop to put the lugs on and I've never thought those things were accurate at all.
Use a simple torque wrench and evenly tighten all nuts to 100 PSI. (i believe that is the correct tightness?)
You should never use an impact wrench on any car, any lug nuts, except to remove them..
Speaking from the perspective of having put about 425K miles on two A*s AND having done more than a few brake jobs on 'em, the rotors on Aerostars will often warp, at least a little, within 3-5K after they're installed. The fact of the matter is that they're woefully undersized for what they're asked to do... Tow anything without a trailer brake? Shazaam! Warped rotors! Actually take a family of five with their luggage on vacation? Abracadabra! Oscillating brake pedal! I'm trying to be funny, but I honestly found that no amount of care (yes, I use a torque wrench when I tighten the lug nuts on all my vehicles...), no expenditure on the best rotors available, would keep the rotors from warping under the "semi-severe duty" of a daily-driver. Don't get me wrong! I've loved my A*s, still own one, and would own more if Ford still made 'em! It's just that's an area where technology has GREATLY advanced since the A* was engineered.
I'll be the disenting opinion. When we first bought our '91, there was a period of time with repeated brake rotor warpage similar to what DadVan describes. Since the van was new the repairs were done either by Ford or specialty brake shops. After the third new set of rotors warped within 6 months of installation, I began looking into what was going on and found the technical bulletins regarding proper torque requirments. Afterwards, I began doing all my own work and have never suffered another problem with warpage. I have pulled trailers and have taken a family of five on numerous long trips to the East coast all without further rotor problems. Along with proper torque, I found cleaning and lubing the brake caliper slides greatly improved the longevity of the brakes and the rotors. So, ln conclusion, I say Aerostar owners can have it all - good brakes and warp free rotors.
Thanx for all the info guys. I've got to say that I've owned a lot of vehicles in the past and I've never had a vehicle that was so touchy on over tightening the lug nuts! I'll replace the rotors if they can't be turned, AND I'll make sure that they are not overtorqued!!