I posted something similar in talk since it is not ford related but got no replies. Are there any other ways to warp rotors other than because of the drivers braking habits? It's a 2003 Honda that is driven easily and the rotors were warped at 30,000 miles and now again at 45,000.
I bought a band new VW Passat with the same problem. The dealer swapped them out & it's been OK over the last 5K miles. But I wonder how they could have gotten that way in the first place. I also had a Saab 900 where the rotors kept warping. They were just to thin & light to be able to take the heat. Maybe you need to go to a different pad material. That was SAAB's solution.
Rotors warp for several reasons as has been suggested. Often the problem develops after the rotors have have been "turned". As the rotor becomes thinner by machining, they become thinner and less able to disapate heat ergo they "warp". Others may simply be defective in which case, replacement id the only real solution.
My sister suburban was warping rotors real bad. Went through 3 set before I found out the rear brakes cylinders were leaking and they were not pulling their share of the load. The fronts were heating up excessively and turning the rotors exacerbated the problem. Have the rear proportioning valve checked also.
Rotors may be sourced from any number of "developing nations" where manufacturing standards may be a little "lax" and not up to the customer's expectations. Ask anyone in the brake business.