Four problems related to brake disc rotor have been reported for the 2005 Saturn Relay. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Saturn Relay based on all problems reported for the 2005 Relay.
Brake rotors have warped 2 twice in the last 2 years. Saturn of beaverton has resurfaced the rotors the first time and had to replace the brakes (fall 2006). The 2nd time they are going to resurface again as far as parts I do not know at this time. Waiting for Saturn to schedule service. (July 2007).
Rotors are warping every 10,000 miles or less, truck vibrates when braking, rotors were repaired or replaced 4 times . I am worried about an underlying problem that could cause an accident.
The contact states there was an ongoing problem with exterior and interior lighting. While driving, the headlights and the dashboard panel lights flickered from bright to dim. Also, the idle was very loud and rough. She took the vehicle to the dealer. The dealer replaced the alternator. This did not correct the problem. The dealer was unable to accurately diagnose the problem, and no further repairs were made. Updated 12/27/2005. The horn springs were deform which resulted in the horn being inoperative. The sliding door would chime as if the door was not closed. The tech adjusted the top middle and bottom latches. The brakes pulsated when braking. The technician had to resurface both front rotors.
Brakes get so hot when traveling down a mountain that it causes the rotors to warp. The van shakes and shimmies and makes a loud sound as if you were traveling over rumble strips on the road. The van exhibited these failures around 15,000 miles. The problem still exists despite the dealer resurfacing the rotors. After driving the vehicle down hill the brakes get hot again and cause the rotors to be warped again.