Hawk HPS with the rear pads almost worn & the front pads were about 70% worn---new rotors all around. Just for kicks, I decided to get ATE Slotted rotors, tyrol caliper bushings & a fresh fluid flush....
i have been told at the dealer that new thickness is approx 25 mm, and replacement size is 23 mm... VW recommends they be done together, but backyard experts & penny pinchers feel that it isn't necessary...... I would never take a chance for the $200 or so that rotors cost it just isn't worth it. if you can't afford $200 for the most critical safety system on your car, perhaps you should take the bus until you can... Very small diameter diferences cause degradation of brake performance, witness when the pads are half worn how low the fluid goes down....that is compensating for the pad wear and ROTOR wear as well......tires & brakes are all that saves your butt in the day-to-day world of insanity out there, don't be foolish.
Contrary to what some people think, the rotors are designed to be replaced when the pads have fully worn down. The tolerance for allowable thickness on our rotors is very small. I don't know the exact number off the top of my head, but IIRC the front rotors on your Jetta are 25mm thick when brand new and the minimum thickness is 23mm. That's not a lot of wiggle room. When the pads are fully gone the rotors will be very close to minimum thickness. You can mic the rotors to test the thickness, but made sure you get past the \"lip\" on the very edge of the rotor or you will get a false reading. Personally, I say don't mess around with brakes. If you only have a few thousand miles on the rotor, than fine - keep it. But if the pads are gone, the rotors are gone too. On a somewhat related note, I just did the brakes on a 2006 Mini for a friend of mine. The tolerance between min and max thickness was only 1.6mm on the front rotors! That's tight.
When I changed the original rotors on my Jetta they required a hell of a fight to get them off. I put anti-sieze on the hub to ensure that would not happen again. When I changed them this past weekend, the rotors came off no problem at all which was nice.
brand new front brake set up (ATE 'atomic' slotted rotors, mintex red box pads, ATE super blue racing fluid)
I have ATE powerdiscs on front and Zimmerman Xdrilled on rear. They both rust. I haven't had any problems yet with warping on either but I installed them about 2-3 monthes ago. I've heard that the Xdrilled can begin cracking around the holes so I'm watching out for this. So far I'm happy with the setup. I also have the mintex redbox pads. Slightly better than OEM and a whole lot less messy. My rims don't collect much dust anymore.
I already have slotted and x-drilled brembo's with pagid blue box all around. I'm in need of replacement since the fronts are warped.
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