My 2006 HHR had brake pulse (front to back) and steering wheel shimmy at all brakng speeds at 20877 miles due to warped front rotors. They were resurfaced - as GM policy prevents dealiers from replacing rotors that have enough depth to resurface. If the dealer replaces "good" rotors under warranty, GM bills the dealer for the parts! Guess what, I now have 41,000 miles - and need new rotors.... because there is not enough metal to resurface again. But, I am out of warranty - and even under my "covers it all" extended warranty - wear items are excluded and brakes are wear items. In contrast, I have a 1993 ford escort wagon with the ORIGINAL rotors/drums - so it's NOT my driving. HHR brakes stink.

Just before first rotor resurface, the left front wheel hub assembly failed causing an ABS failure. This was replaced under warranty. Just before the second rotor problem, the right front wheel hub assembly failed causing an ABS failure and resulting in a single-car accident with side of road (almost 9k in damages). This time GM said it was operator error - so no warranty coverage.

NOTE TO SELF - buy a toyota hybrid next time.

 

My 2006 HHR had brake pulse (front to back) and steering wheel shimmy at all brakng speeds at 20877 miles due to warped front rotors. They were resurfaced - as GM policy prevents dealiers from replacing rotors that have enough depth to resurface. If the dealer replaces "good" rotors under warranty, GM bills the dealer for the parts! Guess what, I now have 41,000 miles - and need new rotors.... because there is not enough metal to resurface again. But, I am out of warranty - and even under my "covers it all" extended warranty - wear items are excluded and brakes are wear items. In contrast, I have a 1993 ford escort wagon with the ORIGINAL rotors/drums - so it's NOT my driving. HHR brakes stink.

Just before first rotor resurface, the left front wheel hub assembly failed causing an ABS failure. This was replaced under warranty. Just before the second rotor problem, the right front wheel hub assembly failed causing an ABS failure and resulting in a single-car accident with side of road (almost 9k in damages). This time GM said it was operator error - so no warranty coverage.

NOTE TO SELF - buy a toyota hybrid next time.

 

I argued to the selling dealer - where I have all work done - that I have never - in 28 years of driving - experienced steering wheel shimmy on rotor/drum warpage/failure across in my ford/toyota/gm/amc products. Was told by service manager - touting asce certification - (like all my prior mechanics) that this was common. Not sure it is - since I have only had the problem in my 2006 HHR. My thought - there is a larger problem in the front end of these vehicles.

Warranty issue: brakes and rotors are wear items typically not covered by warranties. BUT - my first rotor resurface at 20877 mile was covered under warranty. At 41000 miles I need new rotors as there is not enough metal to resurface again. But, now I am out of warranty and GM will not touch it. However, EVERY mechanic I speak to GM/Toyota/Ford/Local folks/backyard tinkerers/street modifiers say, in essence "never resurface, always replace" and "rotors needing service on a new car should be covered under warranty and the rotors should have been REPLACED on the first failure NOT resurfaced."

 

By law they HAVE to. It is a documented recurring problem that originated during the warranty period and was never fully addressed. You should CALMLY speak with your service manager about it. If he doesn't give satisfaction, approach the dealership owner with the problem. If he fails to resolve it - (*and remember - the KEY to getting this resolved is maintaining your cool!), ask him to put you in touch with the GM district rep for your area. There have been many reports of HHR rotor problems in online forums - so GM knows the problem exists.

On the other hand, I replaced my rotors with nickel plated diamond slotted rotors at 4500 miles. Had no problems whatsoever with the stockers, just wanted better braking and "the look." If you need a set of stock rotors, I've got a set I'll sell you (a lot cheaper than buying dealer parts!). Mine are already broken in and trouble-free. Unfortunately, you will probably have to pay quite a bit for shipping, as they are very heavy.

Best of luck with it!

 

That is where I am right now. Trouble is, I have had so many problems with my HHR and this dealership that keeping my cool is so incredibly difficult. Would not be so bad, but the dealership is soooo bad - HERB CHAMBERS CHEBROLET, DANVERS MASSACHUSETTS. They have actually told me I cannot speak to the GM rep! I am going directly through GM - for the third open complaint on this 2 year old car! I have NEVER gone to a manufacturer in almost 30 years of driving.

 

Your quoted experts (or you) forgot one component to the above equation. If you are paying for the repair YOU can REQUEST new rotors and pay for them yourself. You just changed the $200 brake job into a $500 job......and people just don't do that, unless as you suggested the rotor material is less than minimum spec. But frankly, almost every first or second brake job done in America (that is counting ALL dealers, independent brake shops, and the neighborhood repair shop) resurface the rotors. Based on that, I think your mechanic sources quoted above, are all wet. If you believe I'm wrong, I suggest you sit in a brake repair shop for a couple of hours and observe.....you'll be surprised.

Oh, and if the rotors are warped bad enough, it is not unusual for the tire/wheel and steering wheel shimmy to be severe.

But, I'm on your side in this turmoil. Your situation needs to be addressed by the dealer. Continue to pursue that.....reasonably. Based on the latest TSB, you SHOULD get new rotors (mandatory) after 2 resufacings.