Could be the hubs. Mine had an axial throw of 0,02-0,03 mm which I thought wouldn’t affect the discs. I filed a complainment to VW regarding warped discs and they blamed the calipers. Told me one of eight pistons was a bit sluggish. With new calipers and two sets of discs later they found what I had meassured before the complainment, a warped hub. The last pair have not warped after the typical 5000 km mark as before. So at least the floating 365 mm discs are very sensitive regarding straight hubs.
Just an FYI. I just did the brakes and rotors on my LS430. Brake pads are the easiest job ever did. it's just a pin and a clip. Rotors require removing 4 bolts and replacing them as they are drop bolts. Still easiest brake job I have done on a car and I did for around I think 400 with OEM parts
Just the bigger carrier with the bigger rotors on the front. Didn't bother with bigger for the rears. I bought Red Stuff pads.
That being said, it would be great to see a basic writeup with pics of the fronts and rears being changed. I ordered and received some new slotted/drilled rotors with ceramic pads. When ordering, I just used the GTI as the model, since it uses the same brake rotors as the TDI, 312mm F, 272mm R - IIRC. If I have time, I will get some pics and write a rudimentary writeup on it. Not sure if I have time/patience to tackle this myself so I may just have my Audi/VW guy do the work (he has many more tools and 2 lifts). In any case, I will try to get some info and pics in here.
Just discussed this last week. I side with my VW dealer on it. They recommend just replacing the rotors, its really not that much more than having them turned, considering you almost guarantee no pulsation, no shimmy or shudder and more even brake wear.
Engine braking is how I got 60k miles out of the original brake rotors and pads on my '07 GTI as well as a steady 30 mpg while barely trying.
I'm actually running corrado g60 rotors right now that i redrilled to 5 bolt since my last set warped.
I am happy with the R32 setup so far ( rotors are freaking heavy); but if I was to upgrade it would be either AP or stoptech trophies....
Tried aftermarket rotors on my Toyota corolla. Warped them twice within 6 months. Used cheapies from orielly's. Put Toyota rotors on, been fine ever since.
Unfortunately the problem is inherent in the design of the rotors. Not in where they were produced. You can put the best rotors in the world on that car and they will still warp. Vw/Chrysler would need to spec a larger and thicker rotor to help dissipate heat properly. All aftermarkets will make the rotor to fit, based on the crappy oem specs. So, get used to having new rotors put on...because recall or not, Chrysler still needs to redesign that rotor. FYI, I'm in the same boat as you guys! These rotors suck!
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