Brake Disc problems of the 2003 Honda Accord

I believe there is a brake design or manufacturing defect in my 2003 Honda Accord v6. The dealership has replaced the front rotors on my vehicle twice within 37,000 miles. In addition, the front brake pads were replaced once and the rear brake rotors resurfaced once within this milage period. Going through three sets of rotors and one set of brake pads within 37,000 miles means there is either a design or manufacturing defect in the brake system. I experienced no brake failures as a result of these problems.

I purchased my 2003 Accord 4dr about 2 months ago. I started hearing an awful front brake noise at speeds >40mph and the steering wheel would shake. It almost felt like the car wouldn't stop. I'm taking the car into the dealership this evening for this and other issues, however, the service manager seemed as if he had never heard of this problem before. It's annoying to think that the service manager would not be aware of it since it has been so common.

At about the 12k miles, the brakes started to pulse during normal operation. Dealer cut discs and installed new pads. At 24k miles, same situation. Dealer replaced disc and new pads. Dealer could not resolve problem. I am a mechanical engineer and an auto mechanic. The problem is the lower quality steel being used by Honda for their disc brakes. I solved the problem by purchasing ($300 incl shp and handling) american racing disc. I have had no problems since then. Conclusion: Honda is using low quality steel in their disc brakes and has done nothing to improve their product quality. TSB are a poor/cheap way to solve problems.

While driving a noise can be heard, such as squeaking and popping coming from the brakes. Dealer refurbished all the discs on the brake system, which temporarily remedied the problem. Manufacturer was aware of the problem by the complaints he received from several consumers, but had no remedy for the problem.