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Disc Brake System Testing

WARNING: This page is about a different car, the 2002 Oldsmobile Bravada, 2002 GMC Envoy XL, 2002 GMC Envoy, and 2002 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Were you sent here from DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKE? If so, go to next step. If not, see DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKE  under TROUBLE SHOOTING.
  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 (front and/or rear) disc brake pads? If so, go to next step. If not, go to step  12 .
  3. Are any of the (front and/or rear) disc brake pads contaminated? If so, go to step  8 . If not, go to next step.
  4. Are any of the (front and/or rear) disc brake pads worn unevenly? If so, go to step  8 . If not, go to next step.
  5. Are any of the (front and/or rear) 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 FRONT BRAKE PADS  and/or REAR BRAKE PADS  under REMOVAL & INSTALLATION. After repairs are complete, go to step  12 .
    7. CAUTION:

    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 (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: After repairs are complete, 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. Inspect the wheel drive shaft outer seals (boots), if equipped, 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 WHEEL DRIVE SHAFT OUTER JOINT AND SEAL REPLACEMENT, if equipped, in WHEEL DRIVE SHAFTS article. 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. See REAR OIL SEAL AND/OR BEARING REPLACEMENT in appropriate REAR DRIVE AXLE 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. Inspect the following systems for damage and evidence of an external fluid leak. Replace any components found to be leaking fluid which may be the source of the contamination to the pads. Refer to the following:
    • POWER STEERING in STEERING.
    • ENGINE MECHANICAL in ENGINES.
    • AUTOMATIC TRANSMISSION in TRANSMISSIONS.
    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 (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:
    • Binding or seized hardware.
    • Distorted, worn, damaged or missing hardware components.
    Replace the caliper mounting/sliding hardware components as required. See FRONT DISC BRAKE HARDWARE  and/or REAR DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION. Replace the contaminated disc brake pads as a complete axle set. See FRONT BRAKE PADS  and/or REAR BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the cleaning, inspection and replacement? If so, go to next step.
  12. Visually inspect each of the disc brake rotor shields/backing plates for evidence of contact with the brake rotors. Are any of the brake rotor shields/backing plates contacting the brake rotors? If so, go to next step. If not, go to step  14 .
  13. Repair or replace the disc brake rotor shields/backing plates as required. See FRONT DISC BRAKE SPLASH SHIELD  and/or REAR DISC BRAKE BACKING PLATE  under REMOVAL & INSTALLATION. Did you complete the repair or replacement? If so, go to next step.
  14. 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  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  17 .
  15. 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.
    • Lateral runout beyond maximum acceptable level.
    • 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 previously listed conditions, it requires refinishing. Does the brake rotor require refinishing? If so, go to next step. If not, go to step  20 .
  16. Refinish the brake rotor. See BRAKE ROTOR REFINISHING  under ADJUSTMENTS & INSPECTIONS. Inspect the brake rotor thickness. See BRAKE ROTOR THICKNESS  under ADJUSTMENTS & INSPECTIONS. Were you able to REFINISH the brake rotor within the minimum requirements? If so, go to step  20 . If not, go to step  19 .
  17. Is the brake rotor at or below the discard requirements? 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.
    • Lateral runout beyond maximum acceptable level.
    • Thickness variation beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires replacement based upon the results of the inspection. If a brake rotor exhibits any of the previously listed conditions, 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 FRONT BRAKE ROTOR  or REAR BRAKE ROTOR  under REMOVAL & INSTALLATION. After repairs are complete, go to next step.
  20. Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? If so, then system is okay. If system is not okay, go to step  2 .
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