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Rob, I typically change my pads well before they wear down to the point that the brake sensor sets off the lamp on the dash. Why?
Because of heat buildup and the fact that pads are cheap safety insurance. When pads are so thin they'll set off the warning light, they heat up rather quickly with each decent sustained use and you can run the risk of brake fade when you need it most. Plus, the added heat is tough on the calipers, rotors, and fluid.
Tires and brakes. I replace both prematurely because they are the only things on the car keeping me from an accident.
Temper all this with the fact that if your pads have a lot of meat left on them, drive the car like you stole it and don't give it another thought for a couple of months. I inspect my pad wear most every month with a flashlight and peer through the spokes of the wheel. If you pull a wheel off a couple of times and learn just how thick the pad is you'll be able to do this too.
OP: Sorry to hijack your thread!
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