Service Procedure
Please note the following points when performing the Service Procedure:^ When using the on-car brake lathe, prevent metal shavings from contacting or collecting on the ABS speed sensors. Remove any shavings that stick to the ABS speed sensor's magnet. It is best to clean the ABS sensor with the rotor removed.
^ Do not tighten the wheel lug nuts with an air impact driver. Tighten the wheel lug nuts to the proper torque specification. Uneven or high torque applied to the lugs may distort the brake rotor and hub, resulting in increased rotor run-out and excessive rotor thickness variation as the rotor wears.
^ If new rotors are required, install them on the hub in different positions (index) to achieve the lowest run-out reading (equal to or less than 0.0028", 0.07 mm) using a dial indicator. See Figure 2.
^ If the rotor must be removed for any reason, mark the exact location of the rotor (on the axle hub) before removing the rotor (see Figure 1).
^ Check wheel bearing \ hub run-out per the applicable Service Manual
^ If brake judder is caused by the rear brakes, turn the rear brake rotors using the off-car/rotor indexing method.
Rotor Indexing
When installing a new rotor, a rotor that has been surfaced off the car, or a rotor that has been removed for any reason, use the following indexing procedure to ensure the minimum amount of rotor run-out is achieved.
1. Ensure the rotor is fully contacting the hub. Clean the rotor to hub surface if it is rusty.
NOTE:
For cleaning the hub surface, specifically around the wheel studs, it is recommended to use the Wheel Hub Cleaning kit # J-42450-A, which can be ordered from TECH-MATE at 1-800-662-2001.
2. Install the rotor and all lug nuts. Tighten the lug nuts to 40 ft-lbs.
3. Place a reference mark on the rotor and hub (see Figure 1).
4. Measure rotor run-out with a dial indicator (see Figure 2). If the run-out is above 0.0028" (0.07 mm), continue with step 5.
5. Remove the lug nuts and shift the position of the rotor one lug then re-install the lug nuts and torque to 40 ft-lbs.
6. Measure rotor run-out with a dial indicator. Repeat steps 4 and 5 until the rotor is positioned with the least amount of run-out.
7. If run-out exceeds the assembly run-out specification (0.0028", 0.07 mm), new rotors must be turned. For front rotors, use of an on-car brake lathe, such as ProCut(TM) PFM900 or equivalent, (refer to NTB00-013) is required when turning front brake rotors as part of a warranty repair. For rear rotors, use either an on-car (if adaptable) or an off-car brake lathe.
NOTE:
When re-installing the wheels, evenly torque the wheel lug nuts to the proper torque specification (i.e., 98 - 118 N m, 10 - 12 Kg-m, 72 - 87 ft-lb). Do not tighten the wheel lug nuts with an air impact driver.
Brake Pad Shim and Retainer (Hardware Kit) Installation (positioning)
^ Replace the existing "rubber coated" shims and "shim covers" with the new ones supplied in the kit (see Figure 3). Discard the existing (old) rubber coated shims and shim covers. Use PBC grease between the brake pad, shim, and piston to reduce potential noise.
NOTE:
When installing the new shim covers, make sure the cut portion (see Figure 3) is positioned up and against the piston.
^ Install the retainers (contained in the Hardware kit) as shown in Figure 4 (below) and Figure 5
NOTE:
When installing the brake pads, make sure the retainer pin is placed inside the brake pad wear indicator (see Figure 5).
Parking Brake Cable Lever Position (on rear calipers)
Adjust the parking brake cable (referencing the BR section in the applicable service manual) and with the parking brake released, look at the rear brake calipers and make sure the parking brake lever is fully seated against the stopper bolt (see Figure 6). If it is not, check and re-adjust the parking brake cable.
Brake Pad Burnish Procedure
1. Drive the vehicle on a straight smooth road at about 30 MPH (50 Kph).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from about 30 MPH (50 Kph). Adjust the pedal/foot pressure so that the vehicle stopping time is 3-5 seconds, from 30 MPH.
3. Cool the brake system by driving at about 30 MPH (50 Kph) for approximately one minute without stopping.
4. Repeat the above steps (i.e., 1, 2 and 3) between 3 and 5 times to complete the burnishing process.