LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Tracker 2D Utility, RWD, Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> System Testing >> Disc Brake System Testing

Disc Brake System Testing

  1. If you were sent here from SYMPTOMS - HYDRAULIC BRAKE  , go to next step. If you were not sent here from SYMPTOMS - HYDRAULIC BRAKE  , see DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKES  under TROUBLE SHOOTING.
  2. Visually inspect the disc brake pads for the following:
    • Lining thickness.
    • Uneven or abnormal wear edge-to-edge or side-to-side.
    • Evidence of contamination from an external substance
    • Looseness or damage to the pads or to the pad hardware
    Did you find any conditions to indicate a concern with any of the front disc brake pads? If so, go to next step. If not go to step  12 .
  3. Are any of the front disc brake pads contaminated? If so, go to step  8 . If not, go to next step.
  4. Are any of the front disc brake pads worn unevenly? If so, go to step  7 . If not, go to next step.
  5. Are any of the front 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 DISC BRAKE PADS  under REMOVAL & INSTALLATION.
    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 disc brake calipers from the mounting brackets and support the calipers; DO NOT disconnect the hydraulic brake flex hoses from the calipers. See DISC BRAKE CALIPERS  under REMOVAL & INSTALLATION.
    • Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions:
      1. Loose, bent, cracked, or damaged caliper mounting bracket.
      2. Binding or seized hardware.
      3. Worn, damaged or missing hardware components.
    • Replace the caliper bracket, if necessary. See DISC BRAKE CALIPER BRACKETS  under REMOVAL & INSTALLATION.
    • Replace the unevenly-worn, loose or damaged disc brake pads and/or hardware, if necessary. See DISC BRAKE PADS  under REMOVAL & INSTALLATION.
    • After repairs are complete, go to step  12 .
    • Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak.
    • Repair or replace any components found to be leaking brake fluid. Refer to the following procedures as required:
      1. DISC BRAKE CALIPER  under OVERHAUL, or DISC BRAKE CALIPER  under REMOVAL & INSTALLATION
      2. BRAKE HOSES  under REMOVAL & INSTALLATION
      3. BRAKE PIPE  under REMOVAL & INSTALLATION
      See REMOVAL & INSTALLATION  and OVERHAUL  . 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 or boots for damage and evidence of a grease leak. Replace any wheel drive shaft seal or boot that is found to be leaking grease which may be the source of the contamination to the pads. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. 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. Repair or replace any components found to be leaking fluid which may be the source of the contamination to the pads. After repair, go to next step.
    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 contaminants.
    • Remove the front disc brake calipers from the mounting brackets and support the calipers; DO NOT disconnect the hydraulic brake flex hoses from the calipers. See DISC BRAKE CALIPERS  under REMOVAL & INSTALLATION.
    • Inspect the disc brake caliper mounting/sliding hardware for the following conditions:
      1. Binding or seized hardware.
      2. Distorted, worn, damaged or missing hardware components.
    • Replace the disc brake pads and/or the caliper mounting/sliding hardware components, if necessary. See DISC BRAKE PADS  under REMOVAL & INSTALLATION.
    • Did you complete the cleaning, inspection and replacement? If so, go to next step.
    12. NOTE: Disc brake shields that come in contact with disc brake rotors may cause brake system noise.
  12. Visually inspect each of the disc brake rotor shields/backing plates, if equipped, 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 backing plate as required. After repair, 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 MEASUREMENT  under DISC BRAKE SYSTEM in TROUBLE SHOOTING. Does the disc brake rotor meet 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:

    Braking Surface Conditions

    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.

    Braking Surface Wear Conditions

    • 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 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.
    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 MEASUREMENT  under DISC BRAKE SYSTEM in 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 .
  17. Is the brake rotor at or below the discard requirements? If so, go to step  20 .
  18. Inspect each of the disc brake rotors for the following surface and wear conditions:

    Braking Surface Conditions

    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.

    Braking Surface Wear Conditions

    • 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 a 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.
    Does the brake rotor require replacement? If so, go to next step. If not, go to step  20 .
  19. Replace the brake rotor. See DISC 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 .
scientia non olet · About LEMON Manuals