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Disc Brake System Diagnosis

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. If you were sent here from a brake symptom table, go to step  2 . If you were not sent here from a brake symptom table, see DIAGNOSTIC STARTING POINT (HYDRAULIC BRAKES)  under TROUBLE SHOOTING.
  2. Visually inspect the disc brake pads for the following conditions. See BRAKE PAD INSPECTION  under INSPECTION & ADJUSTMENTS. If any conditions were found to indicate a concern with any of the front and/or rear disc brake pads, go to step  3 . If no conditions were found to indicate concern, go to step  12 .
  3. If any of the front and/or rear disc brake pads are contaminated, go to step  8 . If there is no contamination, go to step  4 .
  4. If any of the front and/or rear disc brake pads are worn unevenly, go to step  7 . If the pads are not worn unevenly, go to step  5 .
  5. If any of the front and/or rear disc brake pads and/or pad hardware are loose or damaged, go to step  7 . If none of the pads and/or pad hardware were loose or damaged, go to step  6 .
  6. Remove and inspect the worn disc brake pads for glazing, looseness, heat spots or damage. Replace the worn disc brake pads as a complete axle set. See FRONT BRAKE PADS  and REAR BRAKE PADS  under REMOVAL & INSTALLATION. If the inspection and replacement was completed, go to step  12 .
    7. NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
    • Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. DO NOT disconnect the hydraulic brake flex hoses from the calipers. See FRONT BRAKE CALIPER  and/or REAR BRAKE CALIPER  under REMOVAL & INSTALLATION.
    • Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions: See MOUNTING HARDWARE (FRONT & REAR)  under DISC BRAKE SYSTEM in TROUBLE SHOOTING.
      1. Loose, bent, cracked, or damaged caliper mounting bracket.
      2. Binding or seized hardware.
      3. Worn, damaged or missing hardware components.
    • Replace components as required. Refer to the following procedures in REMOVAL & INSTALLATION as required:
      1. See FRONT BRAKE CALIPER  under REMOVAL & INSTALLATION.
      2. See REAR BRAKE CALIPER  under REMOVAL & INSTALLATION.
      3. See REMOVAL & INSTALLATION (FRONT)  under DISC BRAKE HARDWARE in REMOVAL & INSTALLATION.
    • Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION.
    • If the inspection and the replacements were completed, go to step  12 .
    • Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak.
    • Replace any components found to be leaking brake fluid. Refer to the following procedures as required:
      1. See FRONT CALIPER  under OVERHAUL.
      2. See REAR CALIPERS  under OVERHAUL.
      3. See FRONT BRAKE HOSE  under REMOVAL & INSTALLATION.
      4. See REAR BRAKE HOSE  under REMOVAL & INSTALLATION.
      5. See BRAKE PIPE  under REMOVAL & INSTALLATION.
    If the source of the leak causing contamination of the pads was found and corrected, go to step  11 . If the source of the leak causing contamination of the pads was not found and corrected, go to step  9 .
    9. NOTE: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
    • Inspect the rear axle seals for damage and evidence of a lubricant leak.
    • Replace any rear axle seal that is found to be leaking lubricant which may be the source of the contamination to the pads.
    If the source of the leak causing contamination of the pads was found and corrected, go to step  11 . If the source of the leak causing contamination of the pads was not found and corrected, go to step  10 .
    10. NOTE: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
    • Inspect the following systems for damage and evidence of an external fluid leak.
    • Replace as necessary any components found to be leaking fluid which may be the source of the contamination to the pads. Refer to the following procedures:
      1. If power steering fluid is found, see appropriate RACK & PINION article in SUSPENSION.
      2. See SELF-DIAGNOSTICS - 3.8L CAMARO & FIREBIRD under FAULT ISOLATION in SELF DIAGNOSTICS.
      3. See SELF-DIAGNOSTICS - 5.7L CAMARO & FIREBIRD under FAULT ISOLATION in SELF DIAGNOSTICS.
      4. If there is any cooling line leakage, see appropriate TRANSMISSION/TRANSAXLE article.
    If the source of the leak causing the contamination of the pads was found and corrected, go to step  11 .
    11. NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
    • Clean the remaining disc brake system components to remove any traces of the contaminant.
    • Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. DO NOT disconnect the hydraulic brake flex hoses from the calipers. See FRONT BRAKE CALIPER  and/or REAR BRAKE CALIPER  under REMOVAL & INSTALLATION.
    • Inspect the disc brake caliper mounting/sliding hardware for the following conditions: See MOUNTING HARDWARE (FRONT & REAR)  under DISC BRAKE SYSTEM in TROUBLE SHOOTING.
      1. Binding or seized hardware.
      2. Distorted, worn, damaged or missing hardware components.
    • Replace the caliper mounting/sliding hardware components as required. See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION.
    • Replace the contaminated disc brake pads as a complete axle set. See FRONT BRAKE PADS  and REAR BRAKE PADS  under REMOVAL & INSTALLATION.
    If the cleaning, inspection and replacement has been completed, go to step  12 .
    12. CAUTION: Inspect each rotor individually.
    • Check the thickness of each of the disc brake rotors.
    • Make a determination for each brake rotor if the rotor can be refinished and remain above the minimum requirements.
    If the disc brake rotors meet the minimum requirements for refinishing, go to step  13 . If the disc brake rotors DO NOT meet the minimum requirements for refinishing, go to step  15 . See DISC BRAKE SYSTEM  under TROUBLE SHOOTING.
  13. Inspect each of the disc brake rotors for the following breaking surface and wear conditions:
    • Braking Surface Conditions:
      1. Heavy rust and/or pitting.
      2. Cracks and/or heat spots.
      3. Excessive blueing discoloration.
    • Braking Surface Wear Conditions:
      1. Deep or excessive scoring beyond maximum acceptable level.
      2. Lateral runout beyond maximum acceptable level.
      3. Thickness variation beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. If the brake rotor exhibits any of the following conditions, it requires refinishing.
    • Rotor exhibits one or more of the braking surface conditions listed previously.
    • Rotor is beyond the acceptable level in one or more of the braking surface wear conditions listed previously.
    If the brake rotor requires refinishing, go to step  14 . If the brake rotor does not require refinishing, go to step  18 .
  14. Refinish the brake rotor. Inspect the brake rotor thickness. If you were able to refinish the brake rotor within the minimum requirements, go to step  18 . If you were not able to refinish the brake rotor within the minimum requirements, go to step  17 .
  15. If the brake rotor is at the discard requirements or below, go to step  17 . If the brake rotor is not at the discard requirements or below, go to step  16 .
  16. Inspect each of the disc brake rotors for the following breaking surface and wear conditions:
    • Braking Surface Conditions:
      1. Heavy rust and/or pitting.
      2. Cracks and/or heat spots.
      3. Excessive blueing discoloration.
    • Braking Surface Wear Conditions
      1. Deep or excessive scoring beyond maximum acceptable level.
      2. Lateral runout beyond maximum acceptable level.
      3. Thickness variation beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. If the brake rotor exhibits any of the following conditions, it requires refinishing.
    • Rotor exhibits one or more of the braking surface conditions listed previously.
    • Rotor is beyond the acceptable level in one or more of the braking surface wear conditions listed previously.
    If the brake rotor requires replacement, go to step  17 . If the brake rotor does not require replacement, go to step  18 .
  17. Replace the brake rotor. See FRONT BRAKE ROTOR  and/or REAR BRAKE ROTOR  under REMOVAL & INSTALLATION. If the replacement was completed, go to step  18 .
  18. Install or connect components that were removed or disconnected during diagnosis. If the operation was completed, disc brake system is okay. If the operation was not completed, see step  2 .
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