I bought a 2016 TH new, and off the lot I had brake/vibration problems. I got it into the dealer the same week and they ended up replacing all 4 rotors. They said "because it had sat for several months on the dealer lot they were too rusted to be used". My driving habits with this car are minimal, I work from the home besides the occasional meeting, random store trips, etc, I manage to drive about 1-2 days a week in it, for about 6500miles/yr (I live in the country so it's a trip to go anywhere). Either way it's consistently 1-2 days a week, I've always had/have a sports car, so my driving style is very spirited with hard braking into corners etc. I'm not light footed. The car is also garage parked 100% of the time, and it has seen minimal snow/salt. Standard midwest rain. Okay, so that was the past 2+ years. About 8 weeks ago I started noticing a slight sound sometimes when accelerating from a stop or more specifically taking a hard turn real slow, I was thinking it was a joint/knuckle/something and wasn't overly worried about it. About 4-6 weeks ago the noise started to get worse. About 4 weeks ago I noticed it was everytime I braked and after letting up off the brakes. By this point the noise was a very distinctive metal->metal brake/scraping noise. I was thinking maybe I had a stuck caliper or something. Noticed some light rust around the hub of the outer rotor, but didn't bother to inspect the inner. By this point my braking power in the car was noticeably diminished. I stuck to driving the car once a week until I could get into the dealership today... Sure enough the inner rotor on all 4 wheels was nearly 100% rusted, despite the outters being fine-ish. See attached pic from the dealer. I thought well clearly this is a defect, I have ~16k miles on this car/brakes, I drive it weekly, the outters are fine, it should be covered under my 10 year bumper to bumper warranty? Nope. The cause of my brake problem is "I don't drive the car enough - I need to put at least 12k miles on it a year"... Was the most absurd thing I've ever heard. I literally have a stack of rotors in my garage aging 2-10years that have less rust then these. I have a vehicle parked outside that hasn't moved in a year that looks better then this. Clearly this is the same issue that happened when I got the car, off the lot of the dealer, and now slowly/rapidly-lately, happening again. I don't know if it's the rear dust shield that traps moisture in too well, or if somehow my inner pads aren't contacting well enough, or the metal/materials are deficient. But the dealer wanted 850$ to replace all 4, and after a heated debate, I left with my car and no work done. The problem is it takes me so long and so much of my time to drive to the dealer, two trips cost me more time then it would be if I replaced all of them myself (around 400ish in parts).
My problem/questions here are... Is this a known "feature"? Is there any hope I have of escalating this within Jeep to get it covered? Is it a problem with the metal they use on the rotors themselves maybe? Should I just replace them myself and not try to mess with the dealer anymore? I had a great experience with this dealer getting things fixed when it was less than a year old, but now I'm into a purchased_from_them 10yr bumper-to-bumper extended warranty, the experience is different. Should I file complaints elsewhere? This is definitely a major safety issue.
FYI pic was taken after about a 100 mile hard drive, I guess the little bit of shine you see there was all it managed to actually break free in that time.
Any advice?
Thanks.