This is horrendous. I thought that brake disks were made by a lost-wax casting process, so would be a single piece. Yours seem to be an assembly consisting of inner and outer disks, presumably resistance-welded. If you want to see what a cast disk is (was) like inside, go to this bad example!

Cheers

Clive

Ok looking for a bit of advice really. I have had no replay from any party involved:

Dealer

Skoda UK Technicians

VOSA

Its been over a week now since i sent all the information to all parties and not one has even acknowledged receipt of it. Can anyone give advise on a way forward? As i already said i am in the North Sea at the moment and on nightshift so calling around isnt really an option for another week. On the one occasion i have tried to phone VOSA, i woke up early and gave it a shot, they said they can not help over the phone and all new issues are dealt with via email.

Any assistance/guidance would really be appreciated.

PS - I have the email address of a Robert Hazelwood, is this person still with Skoda as i have read details that he has been promoted?

Edited 25 July, 201213 yr by Graeme B

Have you tried trading standards?

I would say this a bad batch from the foundry.

I have worked in a steel foundry for my sins (which manufactured all the tank tracks for the UK MOD at the time) and for safety critical parts like this, there are a few checks that take place before they even get off the foundry to the machine shop. The chemical composition of each mix of material is checked, then tensile tests are carried out to check the mechanical properties. They should all be radiographed to check for internal flaws, inclusions or porosity and then be crack detected to show any surface tears or shrinkage cracks. Porosity or inclusions are scrap, but some cracks and tears are allowed depending on where they are. I would have thought that none would be allowed for a brake disc.

Also, looking at the photo’s the material looks quite grainy, which could indicate either incorrect chemical composition and/or incorrect heat treatment, which can create the right conditions for crack initiation and propagation. Also, if you look, some of the surfaces are rusty and some are clean which is as you would expect as some of the columns have cracked initially, and then more stress is placed on the remaining ones and you have a cascading effect of cracking and failing with increasing frequency until catastrophic failure occurs.

There certainly could be others out there, as if it was a bad melt or heat as they say, this would only make a certain number of discs berofre a new mix of material is needed. They may also be spread across Europe.

I would be petty ****ed at the garage that said they had replaced them.

Have you tried trading standards?

No i havnt yet

Phone calls I think are next

VOSA probably get a load of stuff every week so I guess its in their system

You could also try a claim for stress caused by the worry, I bet theirs some blood sucking no win no fee nasty legal firm that might fancy a go. I guessWill have to be against the dealer who supplied the car, he then countersuees who he chooses

I have to say, at this point I do think watchdog might be worth while.

Regardless of where the discs come from, OEM or not, there are obviously a few bad discs out there that pose a risk to road users.

Well i have decided to wait till i get home now then do some more emailing, see what i can get out of people. I am home on the 2nd of August all things going well so hopefully will have more updates in the coming week !!

Ok so after being awake for roughly 37 hours i am finally home. I came home to an email from VOSA.

They have requested that i package the discs so that they can be collected as VW Audi group and VOSA would like to inspect them. I know someone mentioned not letting them out of my sight but surely with VOSA in on the act it should all be ok to let them have the discs?!

I just find it funny how when i report it, its not a problem but when VOSA report it suddenly its a huge issue and they will be sending out a courier as soon as possible.

Thoughts?

I cannot see how you can progress this without at some point letting the disks out of your sight. At least VOSA seem to ne taking an interest and VAG won't want the reputational damage that thus case could inflict. You have pictures and umpteen viewers of this forum who have seen those pictures. I would let them have them. Just. my humble opinion...

If they are genuine discs they will have the min wear limit stamped on the edge of the bell of the disc, might have to wire brush it up to see it. In all my days though I've never seen a disc do that.

Take as many pictures as you can, ideally close up pictures.

I cannot see how you can progress this without at some point letting the disks out of your sight. At least VOSA seem to ne taking an interest and VAG won't want the reputational damage that thus case could inflict. You have pictures and umpteen viewers of this forum who have seen those pictures. I would let them have them. Just. my humble opinion...

I would agree, VOSA have a duty to do things properly. Its good you involved them and they appear to be going through due process, they are sending a courier ASAP at no cost to you, it shows some intent on taking it seriously. You have as said plenty of pictures & the proof that it has happened on another car through the link you posted so its not an isolated case. Have you told VOSA about the other instance, I would assume yes but if not include that in any covering letter you send. Even if they are not genuine parts theres a batch of very dangerous disks out there & they need to find the source. It might be worth asking what VOSA will do if they are not genuine parts. Keep on the case as somewhere someone may not be as lucky as you if they arent found

I think it was me that said that but I was really thinking of the dealer not VOSA in terms of holding on to it.

As said lots of close up pics.

If something like that split when you did an emergency stop in a 40 zone, where an adult or kid walked out between cars without looking, I'd say there'd be a good chance of a very nasty mess afterwards.

Are they 288mm or 312mm brakes and as Tech1e said, can you see if they have the limits stamped into the disk (hub area) before you send them off, as this will help determine who made them.

If you can see any logo or part numbers that would also be very helpful.

Ok as usual i appreciate everyones input, i will have a very thorough look at the discs and send them out, anything i can find of any significance i will take photos and post here for info purposes.

As usual will keep everyone posted.

I have now packed the disc and its ready to ship, will be picked up tomorrow.

Just wanted to say that i had a very good look at every surface of the disc and can not find any distinguishing marks or codes.

Once again, thanks to everyone !!

I have now packed the disc and its ready to ship, will be picked up tomorrow.

Just wanted to say that i had a very good look at every surface of the disc and can not find any distinguishing marks or codes.

Once again, thanks to everyone !!

Any updates on this?

Sorry i have been very busy with work and have sent a few emails to VOSA without reply, today i did get a reply, but still unfortunately nothing to report see below:

Dear Mr Bremner,

I apologise if you have not heard from VOSA we did sent a conformation

letter to on the 19th July stating that the case was being investigated

with the manufacturers. this investigation can take a while and we

normally allow two months before chasing the manufacturers. I have attached

a copy of the letter that was sent to you for your records.

As soon as we have any information we will be in touch with you, I have

also attached a copy of the guide to safety defects which explains the role

of VOSA and the purpose of an investigation.

If you have any question please contact me.

I will of course update this thread as soon as i get a response from VOSA or VAG. Thank you for your patients guys !!!

Ok, final update from VOSA/VAG today, thought i would share for an interested persons...

The Vehicle & Operator Services Agency (VOSA) and the manufacturer have now completed the investigation into the above. I am therefore able to inform you of the outcome.

Our acknowledgement letter of 18th July 2012 explained that the purpose any investigation carried out within the terms of the Code of Practice on Vehicle Safety Defects (the Code), which has the support of the General Product Safety Regulations 2005 (as amended), is to establish if the defect is attributable to a design or construction deficiency and is liable to cause a significant risk of personal injury or death.

VW Group UK are satisfied should the disc deteriorate and separate that the brakes would remain fully functional and the driver is alerted to the issue with a clear scrapping noise and some Vibration as you did.

The official response from the manufacturer concludes there is insufficient evidence of a wider problem to warrant an action within the terms of the Code.

Additionally, a search of VOSA’s defects and recalls databases has revealed no similar reports. As such, on this occasion, no further action will be taken.

If you want to discuss this matter in more detail please do not hesitate to contact me.

Thanks, Greame for the update. I see that they haven't clarified if the discs were OE or pattern/ non-VW Grop parts. Avoidance, perhaps? Or simply protecting the Dealer!

Only just found this post .

I worked in a fleet operator workshop servicing transit vans etc. One came in with a brake judder and looking at it the disc on the offside had a crack over the face of the disc,centre to outside rim. The join between the faces where it failed was rusty, as if it was cracked (or not joined properly) for a while then water got into it and as the rust formed forced the two faces apart. The driver reckoned it had only started a week before. These were original parts as the records showed no replacements had been fitted before. As this was about ten years ago it is not a new thing for discs to go like this, admittedly not as dangerous as GraemeBs example.

No they wont admit to them being OE or Non - VW so can take that as you want. The dealer is now no longer trading, they were bought over by Arnold Clark which is why i had trouble finding out what was done to the car before i bought it, i assumed that all documentation would have gone to Arnold Clark but they were just being awkward about it.

Thanks for everyones input once again !!

You'd expect VW to be the first to point out that it's not a genuine part, especially with their big old genuine is better campain.