2006 Outback Brake trouble

[Maliana]

Apologies if this is a repost -- I'm new to the group, and not terribly skilled at this process.

At 27000 km, my 2006 Outback had all four rotors replaced under warranty due to warping. At 39,370 kms the rotors had to be machined, and all pads replaced -- I paid for that. And at 74,731 kms, and off warranty, the car immediately needed four new rotors and pads. I was horrified.

I'm a cautious driver who diligently maintains her vehicle with regular servicing, always undertaken at a Subaru dealership. I do extensive highway driving, so not a lot of starts and stops. Nor do I "ride" the brakes. The service head at the dealership has no explanation for the problem, but Subaru Canada insists this is a matter of "normal wear and tear," and refuses to accept any responsibility past a "goodwill gesture" that covers the replacement of two of the rotors. I'm convinced that there's a deeper issue here, and that I'm dealing with an inherent defect of some kind.

No one I know (Subaru owner or otherwise) has ever heard of such a situation. And I've never had any brake issues at all with the six cars I've owned over the years, which included both a high-performance vehicle and an SUV.

Has anyone else had any similar problems with the car? If so, I'd be very keen to know how you've handled it. This problem has been a source of great anxiety for me, and I'd appreciate any suggestions as to how to deal with it.

[PITTSBURGH]

Make sure they are tightening your lug nuts at 88.5ft-lbs.
I had the same issue with mine.Over tightening lug nuts will warp rotors.

[Maliana]

Thanks for the suggestion. Much appreciated.