New as in I bought it new. 36,000 mile warranty and at around 36,000 miles I had to replace all 4 rotors, not cut but replace (not a warranty issue anyways.) That was about $500 including pads (parts only.) I count that because it had only 36k miles on it. Never had to replace rotors before and I haven't owned a vehicle yet that had less than 170,000 miles when I sold it. Bushing was slightly torn in the control arm, replace bushing? Nope, replace the entire control arm, $169 for part only. That was at 60k miles. Week later the speed sensor ring broke rendering the brakes useless and the vehicle undriveable because of stupid anti-lock brakes kicking in as soon as you hit the brakes, aka, no stopping. $5 replacement for the speed sensor ring? Nope, have to replace the entire axle, was $69 I think and more work than I could handle since I had just had the suspension torn apart the previous week and didn't want to go through that hassle again. So I also spent $90 on labor.Interesting, the most recent Consumer Reports survey (April 2010) put Ford ahead of Toyota, Honda, Lexus and Acura in reliability.
And if it's new, it should still all be under warranty.
As for an 89 Toyota, 88 Toyota, 94 Toyota, 99 Toyota, and 96 Nissan, I've replaced 2 rotors (165,000 miles, same day I replaced the junk Ford at 36,000 miles) for $250. Clutch went into one of the Toyotas at $130. That's all I replaced on 5 vehicles with a combined total of almost 500,000 miles on them other than normal routine maintenance like tires, brake pads, and shocks/struts.
Total of $380 in 5 vehicles and 500,000 miles or roughly $740 not including labor in less than 60,000 miles on the Ford. I think the math is pretty simple along with the fact that none of the Japanese cars had ever broken like the control arm or sensor ring of the Ford rendering the vehicles undriveable. You can argue about the rotors being a normal maintenance thing, but I don't consider it normal when the vehicle only has 36,000 miles. I bought new because I didn't want to have to do all the "normal maintenance" on major stuff for a while. Turns out, I would probably have been better off with a 100,000 mile Japanese car because the big maintenance items still wouldn't have been done as early.
BTW, those Ford rotors are still sitting in my garage where they've been sitting for a year now next to the 165,000 mile Nissan rotors. I have a bunch of scrap metal to take to the recycler, thus I went to pick them up to put with the rest of the scrap metal. They literally are nearly completely gone and just a pile of rust. Not rusty hunks of metal, but literally a pile of rust. I swept up my old Ford rotors with a broom and dustpan, then picked up the Nissan rotors that still look the same as when I removed them from the car except for some rust on the surface like you would expect. All I have left from the Ford is the center hub part, the actual disc section is gone.


