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Disc Brake System Test

  1. If sent here from SYMPTOM INDEX  table, go to next step. If not sent here from SYMPTOM INDEX  table, perform HYDRAULIC BRAKE DIAGNOSTIC SYSTEM CHECK  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).
    • Looseness or damage (including pad hardware).
    • Evidence of contamination from an external substance.
    See BRAKE PAD INSPECTION  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS. If any problems with brake pads are found, go to next step. If no problems are found, go to step  12.
  3. If any of the disc brake pads are contaminated, go to step  8. If brake pads are not contaminated, go to next step.
  4. If any of the disc brake pads are worn unevenly, go to step  7. If brake pads are not worn unevenly, go to next step.
  5. If any of the disc brake pads and/or pad hardware are loose or damaged, go to step  7. If brake pads and/or pad hardware are not loose or damaged, 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. After inspection and replacement, go to step  12.
    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. Perform the following:
    1. Remove the 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 BRAKE CALIPER  under REMOVAL & INSTALLATION.
    2. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions:
      • Binding or seized hardware.
      • Worn, damaged or missing hardware components.
      • Loose, bent, cracked, or damaged caliper mounting bracket.
      See BRAKE MOUNTING & HARDWARE INSPECTION  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS.
    3. Replace components as required. Refer to the following procedures as required:
    4. Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. See BRAKE PADS  under REMOVAL & INSTALLATION. After inspection and replacement, 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: If source of the leak causing pad contamination is found, go to step  11. If source of the leak is not found, go to next step.
  9. Inspect the wheel drive shaft outer seals for damage and evidence of a grease leak. Replace any wheel drive shaft seal that is found to be leaking grease which may be the source of the pad contamination. See appropriate AXLE SHAFTS article in DRIVE AXLES. If source of the leak causing pad contamination, go to step  11. If source of the leak is not found, go to next step.
  10. Perform the following;
    1. 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.
    2. 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.
    3. Replace any components found to be leaking fluid which may be the source of the contamination to the pads.
    If source of the leak causing pad contamination was found and corrected, go to next step.
    CAUTION: 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.
  11. Perform the following:
    1. Clean the remaining disc brake system components to remove any traces of the contaminant.
    2. Remove the 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 BRAKE CALIPER  under REMOVAL & INSTALLATION.
    3. Inspect the disc brake caliper mounting/sliding hardware for the following conditions:
      • Binding or seized hardware.
      • Distorted, worn, damaged or missing hardware components.
      See BRAKE MOUNTING & HARDWARE INSPECTION  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS.
    4. Replace the caliper mounting/sliding hardware components as required. See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION.
    5. Replace the contaminated disc brake pads as a complete axle set. See BRAKE PADS  under REMOVAL & INSTALLATION.
    After replacement, 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  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS. If the disc brake rotor meets the minimum requirements for refinishing, go to next step. If the disc brake rotor does not meet the minimum requirements for refinishing, go to step  16.
  13. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. See BRAKE ROTOR THICKNESS VARIATION MEASUREMENT  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS. If the brake rotor exhibits thickness variation that exceeds the maximum acceptable level, go to step  15. If the brake rotor thickness variation does not exceed the maximum acceptable level, go to next step.
  14. Perform the following:
    1. 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. See BRAKE ROTOR SURFACE & WEAR INSPECTION  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS.
    2. 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 listed conditions, it requires refinishing. If the brake rotor require refinishing, go to next step. If the brake rotor does not require refinishing, go to step  20.
  15. Refinish the brake rotor. See BRAKE ROTOR REFINISHING  in ADJUSTMENTS & INSPECTIONS. Inspect the brake rotor thickness. See BRAKE ROTOR THICKNESS MEASUREMENT  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS. If the brake rotor was able to be refinished within the minimum requirements, go to step  20. If the brake rotor was not able to be refinished within the minimum requirements, go to step  19.
  16. If the brake rotor is at or below the DISCARD requirements, go to step  19. If the brake rotor is not at or below the DISCARD requirements, go to next step.
  17. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. See BRAKE ROTOR THICKNESS VARIATION MEASUREMENT  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS. If the brake rotor exhibits thickness variation that exceeds the maximum acceptable level, go to step  19. If the brake rotor thickness variation does not exceed the maximum acceptable level, go to next step.
  18. Perform the following:
    1. 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. See BRAKE ROTOR SURFACE & WEAR INSPECTION  under DISC BRAKE SYSTEM in ADJUSTMENTS & INSPECTIONS.
    2. 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 previous conditions, it requires replacement.
    If the brake rotor requires replacement, go to next step. If the brake rotor does not require replacement, go to step  20.
    NOTE: Whenever a brake rotor is replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes.
  19. Replace the brake rotor. See BRAKE ROTOR  under REMOVAL & INSTALLATION. After replacement, go to step  22.
  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 MEASUREMENT  under ADJUSTMENTS & INSPECTIONS. If the brake rotor exhibits assembled LRO that exceeds the maximum acceptable level, go to next step. If the brake rotor does not exceed the maximum acceptable level, go to step  22.
  21. Correct the assembled lateral runout (LRO) for each brake rotor that was determined to have LRO exceeding the maximum acceptable level. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT CORRECTION  under ADJUSTMENTS & INSPECTIONS. After correction, go to next step.
  22. Install or connect components that were removed or disconnected during diagnosis. If procedure is completed, the disc brake system is okay. Go to SYMPTOM INDEX  table.
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