John Boy

The Brake Pad Warning Lights just came on my 2012 S5 Carbrio but I still have 6MM of pad left. The dealer told me that the problem is that the Outer Lip on my Rotor was cutting into my Wear Sensor. Any suggestions short of replacing both pads and rotors?

Tirgoman

Hard to tell without pics but I'd get the dealer to take you to the shop and show you. Should be pretty easy for you to see if what he's telling you makes sense. The brake wear sensor is pretty simple, a wire goes to a small metal sensor touches the titor when the pads where down. Touching the rotor causes the light to go on. If the motor is touching the sensor and the pads are not worn down is strange.

J. Patterson

What he is telling you is true. The wear sensor is at the edge of the pad. As rotors wear and develop a lip at the edge, that lip cuts into the wear sensor sooner. If it were mine I would disable the wear sensor by clipping the wires ( at the sensor) and twisting them together and wrapping with electrical tape. This is common practice for track days and pads that don’t have sensors. You could then run those rotors until the pads are used up. Then you’ll need to replace pads rotors and sensors but it will be a while.