Five problems related to brake disc rotor have been reported for the 1997 Honda Civic. The most recently reported issues are listed below.
Rotors have warped repeatedly, I only noticed due to the pulsation when I applied the brakes. Seems to be consistently happening every 25,000 to 30,000 miles. I have a CO-worker who bought the same make and model 30 days before we did who is experiencing the same problem. He has had to have his turned 3 times, and finally bought replacement rotors at 90,000 miles. If this is not caught by the owner, or during a routing inspection, the brake system may fail to function properly, resulting in crashes and possible fatalities.
Repeated warping of brake rotor with severe vibration at highway speed whenever brakes applied. Turning (resurfacing) rotor only solves problem for 10,000 miles. Dealer wouldn't cover under warranty & insists vibration does not affect safety. I do not believe this, as steering wheel jerks violently at higher speeds.
Brake rotors failed two time in 20,000 miles, first repair at 9,000 miles, rotors warped causing extreme vibration while braking.
The front rotors have now twice failed in 21,000 miles, due to excessive warping. The first failure occurred at 9,000 miles; the second began at approximately 20,000 miles and became increasingly more severe. Honda has provided no colorable explanation for why this would occur. With respect to driving, the local Honda dealer claims that this poses no safety issue. I respectfully disagree. The warping has resulted in severe shimmying in the car (and, at some speeds, a hard and sudden pull) upon application of the brakes, affecting both steering and stopping, and overall handling. Despite the car's relatively low mileage, the local Honda dealer (sf Honda) has deemed this to be a "regular" wear and tear item, and thus only machined down the rotors to resolve the most recent warping. I have never heard of (or experienced) such rotor warping in 15 years of driving. I am also confirming by letter (copied to the dealer and the manufacturer) the substance of this questionnaire. I further note that a technical service bulletin has previously been issued with respect to the 1997 Civic's brakes.
Brake rotors needed to be replaced 4 times within 45,000 due to poor rotor design.