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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. When inspection and replacement are complete, go to step  10 .
    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.
    • Did you complete the inspection and replacement? If so, go to step  12 .
    • Inspect the vehicle for an obvious source of a fluid leak. Repair as necessary.
    • 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
      Did you find and correct the source of the leak causing contamination of the pads? If so, go to next step.
  9. Clean the remaining disc brake system components in order to remove any traces of contamination. DO NOT disconnect the hydraulic brake flex hoses from the calipers. Remove the front disc brake calipers from the mounting brackets and support the calipers. See DISC BRAKE CALIPERS  under REMOVAL & INSTALLATION. Inspect the disc brake caliper mounting and hardware for the following conditions:
    • Binding Or Seized Hardware
    • Distorted, Worn, Damaged Or Missing Hardware Components
    Replace the caliper hardware components, if necessary. See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION. Replace the disc brake pads as a complete axle set. See DISC BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the cleaning, inspection and replacement? If so, go to next step.
  10. Visually inspect each of the disc brake rotor shields for evidence of contact with the brake rotors. Are any of the brake rotor shields contacting the brake rotors? If so, go to next step. If not, go to step  12 .
  11. Repair or replace the disc brake rotor shields as necessary. See DISC BRAKE SPLASH SHIELD  under REMOVAL & INSTALLATION. Did you complete the repair or replacement? If so, go to next step.
  12. Measure 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. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. See BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. 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 The Maximum Acceptable Level
    Make a determination for each brake rotor if the rotor requires refinishing based on the results of the inspection. Does the disc 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 ADJUSTMENTS & INSPECTIONS. Measure the brake rotor thickness. See BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Were you able to refinish the brake rotor within the minimum requirement? 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 . If not, 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 MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. 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 the maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires replacement based upon the results of the inspection. Does the brake rotor require replacement? If so, go to next step. If not, go to step  20 .
    19. NOTE: Measure the assembled lateral runout (LRO) after replacing the brake rotor in order to ensure optimum performance of the disc brakes. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT  under ADJUSTMENTS & INSPECTIONS.
  19. Replace the brake rotor. See DISC BRAKE ROTOR  under REMOVAL & INSTALLATION. Did you complete the replacement? If so, go to next step.
  20. Inspect each of the disc brake rotors for assembled lateral runout (LRO). See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT  under ADJUSTMENTS & INSPECTIONS. Does the brake rotor assembled LRO exceed the maximum acceptable level? If so, go to next step. If not, go to step  22 .
  21. Correct the brake rotor assembled LRO. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION  . 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? If so, system okay. If system is not okay, go to step  2 .
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