Test Description
The numbers below refer to the step numbers on the diagnostic table:
9. Lubricant leaks from non-brake system components may come in contact with and
contaminate brake system components.
10. Lubricant leaks from non-brake system components may come in contact with and
contaminate brake system components.
12. Disc brake rotor shields/backing plates that come in contact with disc brake rotors may
cause brake system noise.
15. Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause
brake pulsation.
19. Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause
brake pulsation.
22. Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level
can lead to thickness variation.
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Step |
Action |
Yes |
No |
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DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake system in order to determine if the DISC brake system is operating properly. You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate. |
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1 |
Were you sent here from a Brake Symptom table? |
Go to Step 2 |
Go to Symptoms - Hydraulic Brakes |
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2 |
Visually inspect the disc brake pads for the following conditions: Brake Pad Inspection. Lining thickness below specifications 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 Did you find any conditions to indicate a concern with any of the front and/or rear disc brake pads? |
Go to Step 3 |
Go to Step 12 |
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3 |
Are any of the front and/or rear disc brake pads contaminated? |
Go to Step 8 |
Go to Step 4 |
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4 |
Are any of the front and/or rear disc brake pads worn unevenly? |
Go to Step 7 |
Go to Step 5 |
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Action |
Yes |
No |
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5 |
Are any of the front and/or rear disc brake pads and/or pad hardware loose or damaged? |
Go to Step 7 |
Go to Step 6 |
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6 |
1. Remove and inspect the worn disc brake pads for glazing, looseness, heat spots or damage. 2. Replace the worn disc brake pads as a complete axle set. Front Disc Brake Pads Replacement Rear Disc Brake Pads Replacement Did you complete the inspection and replacement? |
Go to Step 12 |
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7 |
Caution: Support the brake caliper with heavy mechanic 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. Note: Do NOT disconnect the hydraulic brake flex hoses from the calipers. 1. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. Front Brake Caliper Replacement Rear Brake Caliper Replacement 2. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware. Front Disc Brake Mounting and Hardware Inspection Rear Disc Brake Mounting and Hardware Inspection 3. Identify any components with the following conditions. Binding or seized hardware Worn, damaged or missing hardware components Loose, bent, cracked, or damaged caliper mounting bracket 4. Replace components as required. Rear Brake Caliper Bracket Replacement 5. Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. |
Go to Step 12 |
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Step |
Action |
Yes |
No |
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Rear Disc Brake Pads Replacement Did you complete the inspection and replacement? |
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8 |
1. Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak. 2. Replace any components found to be leaking brake fluid. Front Brake Caliper Overhaul or Front Brake Caliper Replacement Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement Front Brake Hose Replacement Rear Brake Hose Replacement Brake Pipe Replacement Did you find and correct the source of the leak causing contamination of the pads? |
Go to Step 11 |
Go to Step 9 |
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9 |
1. Inspect the wheel drive shaft outer seals, if equipped, for damage and evidence of a grease leak. 2. Replace any wheel drive shaft seal that is found to be leaking grease which may be the source of the contamination to the pads. 3. Inspect the rear axle seals for damage and evidence of a lubricant leak. 4. Replace any rear axle seal that is found to be leaking lubricant 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? |
Go to Step 11 |
Go to Step 10 |
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10 |
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. |
Go to Step 11 |
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Step |
Action |
Yes |
No |
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Did you find and correct the source of the leak causing contamination of the pads? |
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11 |
1. Clean the remaining disc brake system components to remove any traces of the contaminant. Caution: Support the brake caliper with heavy mechanic 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. Note: Do NOT disconnect the hydraulic brake flex hoses from the calipers. 2. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. Front Brake Caliper Replacement Rear Brake Caliper Replacement 3. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware. Front Disc Brake Mounting and Hardware Inspection Rear Disc Brake Mounting and Hardware Inspection 4. Identify any components with the following conditions. Binding or seized hardware Worn, damaged or missing hardware components Loose, bent, cracked, or damaged caliper mounting bracket 5. Replace components as required. Rear Brake Caliper Bracket Replacement 6. Replace the contaminated disc brake pads as a complete axle set. Front Disc Brake Pads Replacement Rear Disc Brake Pads Replacement Did you complete the cleaning, inspection and replacement? |
Go to Step 12 |
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12 |
Visually inspect each of the disc brake rotor shields/backing plates for evidence of contact with |
Go to Step 13 |
Go to Step 14 |
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Step |
Action |
Yes |
No |
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the brake rotors. Are any of the brake rotor shields/backing plates contacting the brake rotors? |
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13 |
Repair or replace the disc brake rotor shields/backing plates as required. Front Brake Shield Replacement Rear Brake Shield Replacement Did you complete the repair or replacement? |
Go to Step 14 |
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14 |
1. Check the thickness of each of the disc brake rotors. Note: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. 2. Make a determination for each brake rotor if the rotor can be REFINISHED and REMAIN ABOVE the minimum requirements. Brake Rotor Thickness Measurement Does the disc brake rotor meet the minimum requirements for REFINISHING? |
Go to Step 15 |
Go to Step 18 |
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15 |
Note: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. Brake Rotor Thickness Variation Measurement Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? |
Go to Step 17 |
Go to Step 16 |
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16 |
1. Inspect each of the disc brake rotors for the following surface and wear conditions: Brake Rotor Surface and Wear Inspection Heavy rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Deep or excessive scoring beyond maximum acceptable level Note: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. 2. Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. |
Go to Step 17 |
Go to Step 22 |
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Step |
Action |
Yes |
No |
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If the brake rotor exhibits any of the conditions listed previously, it requires refinishing. Does the brake rotor require REFINISHING? |
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17 |
1. Refinish the brake rotor. Brake Rotor Refinishing 2. Inspect the brake rotor thickness. Brake Rotor Thickness Measurement Were you able to REFINISH the brake rotor within the minimum requirements? |
Go to Step 22 |
Go to Step 21 |
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18 |
Is the brake rotor at or below the DISCARD requirements? |
Go to Step 21 |
Go to Step 19 |
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19 |
Note: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. Brake Rotor Thickness Variation Measurement Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? |
Go to Step 21 |
Go to Step 20 |
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20 |
1. Inspect each of the disc brake rotors for the following surface and wear conditions: Brake Rotor Surface and Wear Inspection Heavy rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Deep or excessive scoring beyond maximum acceptable level Note: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. 2. 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? |
Go to Step 21 |
Go to Step 22 |
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21 |
Note: Whenever a brake rotor is replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum |
Go to Step 24 |
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Action |
Yes |
No |
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Replace the brake rotor. Front Brake Rotor Replacement Rear Brake Rotor Replacement Did you complete the replacement? |
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| 22 |
Note: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for assembled LRO that exceeds the maximum acceptable level. Brake Rotor Assembled Lateral Runout Measurement Does the brake rotor exhibit assembled LRO that exceeds the maximum acceptable level? |
Go to Step 23 |
Go to Step 24 |
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Correct the LRO for each brake rotor that was determined to have LRO exceeding the maximum acceptable level. Brake Rotor Assembled Lateral Runout Correction Did you complete the operation? |
Go to Step 24 |
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| 24 |
Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? |
Disc Brake System OK Return to Symptom Table |
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