Hi all, my first post here so sorry if it's in the wrong section.

I have a 2005 Mondeo 2.2 tdci that has developed a very annoying problem. I had the front discs and pads changed as they were getting low, after a month or so I felt a tiny judder which slowly got worse, so the garage replaced the discs and pads again under warranty. The juddering has returned and I am at a loss as to what could be causing this. I don't drive it hard or do heavy braking from speed, so there must be an issue someehere. Yes it's an old car with 150k on the clock, but I have owned it for 6 years, it was 9 years old when I got it, with only 60k on the clock, and a 1 owner full ford history! I have maintained it well and it drives great apart from this brake problem. Does anyone have any clue as to what could cause this? I can't afford to replace the car, and I had the clutch and flywheel done a few months ago so plan on keeping it for some time!

Any thought or ideas are most welcome, many thanks

I’d want to see the prep work done in the process of fitting the new discs and pads. 
Also, what brand of parts are being fitted? 
 

Runout in the hub caused by rust build up/surface not being cleaned properly is a popular problem. 

On 9/9/2020 at 5:54 PM, stef123 said:

I’d want to see the prep work done in the process of fitting the new discs and pads. 
Also, what brand of parts are being fitted? 
 

Runout in the hub caused by rust build up/surface not being cleaned properly is a popular problem. 

I'd also be interested to know what brand discs and pads are being fitted.  For reference some of my less positive experiences on my MK2 Focus are:

• Brembo pads (from EuroCarParts) - Definitely didn't perform like a performance pad
• Brembo discs - Rust like a ba*stard and after a 1000 miles bedding in process they warped after 4000 miles
• Eicher (utter *****, just...DON'T)
• Bosch discs (from EuroCarParts) just removed them from my MK2 after 2.5 years, rusted to f*ck, that soft the pads had ground a deep enough groove that it left a big lip on the edge of the disc that made a lovely grinding sound the 1st time I braked each day and the centre hub of the disc looks dreadful (unlike the coated Pagid discs on the front that still look mint, seem to have barely worn using the same pads and the centre hub of the disc still looks good).

I find genuine Ford discs and pads the way to go

As others have said - the fitting/preparation process is most critical - ensure hub flange is spotless and rust free etc.

The ultimate is to check disc run out - if new discs show a "runout" and the hub is perfectly clean, it will be a distorted hub which requires replacement.

I know Focus hubs distort very easily, even the slightest knock of the wheel rim on a kerb will distort a Focus hub

 

BrakeDisc Run Out.pdf

I just replaced a set of discs and pads today for a customer. Complaint was brake squeal and a brake judder. Discs and pads were only fitted months ago by a big well known garage.

Upon stripping the brakes down it was clear to me the cause of failure, the cheap crap unbranded parts for one but mainly the huge amount of rust build up on the hub face! very disappointing.