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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 112 (Disc Brakes & Drum Brakes) >> System Tests >> Disc Brake System Testing >> Test Procedure

Test Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Were you sent here from Brake Symptom table? If so, go to next step. If not, go to DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKES  .
  2. Visually inspect the disc brake pads for the following:
    • Lining thickness
    • Uneven and/or abnormal wear - edge-to-edge and/or side-to-side.
    • Evidence of contamination from an external substance.
    • Looseness or damage - including pad hardware.
    Did you find any conditions to indicate a concern with any of the disc brake pads? If so, go to next step. If not, go to step  12
  3. Are any of the disc brake pads contaminated? If so, go to step  8 . If not, go to next step.
  4. Are any of the disc brake pads worn unevenly? If so, go to step  7 . If not, go to next step.
  5. Are any of the disc brake pads and/or pad hardware loose or damaged? If so, go to step  7 . If not, go to next step.
  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 BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the inspection and replacement? If so, go to step  12 .
    7. NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's 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.
  7. Remove the disc brake calipers from the steering knuckles and support the calipers. See BRAKE CALIPER  under REMOVAL & INSTALLATION. Inspect the steering knuckle and the mounting/sliding hardware for the following conditions:
    • Loose, bent, cracked, or damaged caliper mounting bracket.
    • Binding or seized hardware.
    • Worn, damaged or missing hardware components.
    Replace components as required. Refer to the following procedures as required:
    • See appropriate STEERING KNUCKLE REPLACEMENT in FRONT SUSPENSION article.
    • See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION.
    Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. See BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the inspection and replacement? If so, go to step  12 .
  8. 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: Did you find and correct the source of the leak causing contamination of the pads? If so, go to step  11 . If not, go to next step.
    9. NOTE: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
  9. Inspect the wheel drive shaft outer seals (boots) for damage and evidence of a grease leak. Replace any wheel drive shaft seal (boot) that is found to be leaking grease which may be the source of the contamination to the pads. See appropriate FRONT DRIVE AXLES article. Did you find and correct the source of the leak causing contamination of the pads? If so, go to step  11 . If not, go to next step.
    10. NOTE: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
  10. Inspect the automatic transmission cooling system lines, if equipped, for damage and evidence of an external fluid leak which may be the source of the contamination to the pads. Inspect the power steering system hoses for damage and evidence of an external fluid leak which may be the source of the contamination to the pads. Replace any components found to be leaking fluid which may be the source of the contamination to the pads. Did you find and correct the source of the leak causing contamination of the pads? If so, go to next step.
  11. Clean the remaining disc brake system components to remove any traces of the contaminant. Remove the disc brake calipers, as appropriate, from the mounting brackets and support the calipers. Do NOT disconnect the hydraulic brake flexible hoses from the calipers. See FRONT BRAKE CALIPER  under REMOVAL & INSTALLATION. Inspect the disc brake caliper mounting/sliding hardware for the following conditions:
    • Binding or seized hardware.
    • 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 BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the cleaning, inspection and replacement? If so, go to next step.
  12. 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. See BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Does the disc brake rotor meet the minimum requirements for REFINISHING? If so, go to next step. If not, go to step  16 .
    13. NOTE: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
  13. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. See BRAKE ROTOR THICKNESS VARIATION MEASUREMENT  in DISC BRAKE SYSTEM under TROUBLE SHOOTING. Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? If so, go to step  15 . If not, go to next step.
  14. Inspect each of the disc brake rotors for the following surface and wear conditions:
    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.
    • Deep or excessive scoring 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 conditions listed previously, it requires refinishing. Does the brake rotor require REFINISHING? If so, go to next step. If not, go to step  20 .
  15. Refinish the brake rotor. See BRAKE ROTOR REFINISHING  in DISC BRAKE SYSTEM under TROUBLE SHOOTING. Inspect the brake rotor thickness. BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under TROUBLE SHOOTING. Were you able to refinish the brake rotor within the minimum requirements? If so, go to step  20 . If not, go to step  19 .
  16. Is the brake rotor at or below the discard requirements? If so, go to step  19 . If not, go to next step.
    17. NOTE: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
  17. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. See BRAKE ROTOR THICKNESS VARIATION MEASUREMENT  in DISC BRAKE SYSTEM under TROUBLE SHOOTING. Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? If so, go to step  19 . If not, go to next step.
  18. Inspect each of the disc brake rotors for the following surface and wear conditions:
    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.
    • Deep or excessive scoring beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires replacement based upon the results of the inspection. If the brake rotor exhibits any of the conditions listed previously, it requires replacement. Does the brake rotor require REPLACEMENT? If so, go to next step. If not, go to step  20 .
  19. Replace the brake rotor. See BRAKE ROTOR  under REMOVAL & INSTALLATION. Did you complete the replacement? If so, go to step  22 .
    20. NOTE: Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to thickness variation.
  20. Inspect each of the disc brake rotors for assembled lateral runout (LRO) that exceeds the maximum acceptable level. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT  under ADJUSTMENTS & INSPECTIONS. Does the brake rotor exhibit assembled LRO that exceeds the maximum acceptable level? If so, go to next step. If not, go to step  22 .
  21. Correct the LRO for each brake rotor that was determined to have LRO exceeding the maximum acceptable level. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION  under ADJUSTMENTS & INSPECTIONS. Did you complete the operation? If so, go to next step.
  22. Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? Then system is okay. If system is not okay, go to step  2 .
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