Brakes - Service Procedures and Guidelines: Overview
Bulletin No.: 05-05-22-002Date: June 20, 2005
WARRANTY ADMINISTRATION
Subject:
Brake Warranty Service and Procedures
Models:
1999-2006 Saturn Vehicles (U.S. Only)
Important:
Saturn retailers in Canada should refer to Corporate Bulletin Number 00-05-22-002F.
Important:
PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE.
Important:
For all warranty brake service, the procedures in this bulletin must be followed.
For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, reference Service Technical College Courses 030523005T1,15045.10W, 15045.10D1&D2, 15045.10H and 15040.01V.
There are five (5) key steps that must be performed to complete a successful brake service:
1. Measure and Document Rotor Thickness* - determine rotor refinish/replace
2. Clean Mating Surfaces - hub, rotor and wheel
3. Proper Rotor Refinish and Documentation
4. Measure, Document and Correct Lateral Run Out (LRO)** - Maximum 0.050 mm (0.002 in)
5. Reassemble with Proper Torque - wheel lug nuts
*The bulletin refers to Minimum Thickness specification (stamped on the back of the rotor) as the minimum allowable thickness after refinish. Refer to SI to verify specifications.
**The bulletin will refer to LRO maximum specification as 0.050 mm (0.002 in). However, some trucks may slightly differ.
Refer to SI to verify specifications.
Bulletin Format/Key Page Number
Reference:
***CUSTOMER SERVICE ORDER/WARRANTY CLAIM REQUIRED DOCUMENTATION
Important:
When using any one of the brake labor operations listed in this bulletin, the following three rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness and 3. Lateral Run Out) are required and MUST be written/documented on the customer service order, or for your convenience, complete the form (GM Brake Service customer service order Documentation for Required Measurements) found on the last page of this bulletin and attach it to the customer service order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the customer service order that is sent back.
Important:
Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request.
Customer Service Order Documentation - Rotor Original And Refinished Thickness - REQUIRED
When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the customer service order hard copy for each rotor serviced. If a rotor replacement is necessary, only the Original thickness measurement needs to be recorded.
Customer Service Order Documentation - Lateral Run Out (LRO) and Correctional Plate Part Number - REQUIRED
When using any one of the brake labor operations listed in this bulletin, the rotor assembly MUST be measured for Lateral Run Out (LRO) (follow brake procedure steps 9-11). If the LRO measurement is greater than 0.050 mm (0.002 in), correct it by using the proper Brake Align� Correctional Plate (DO NOT refinish new rotors or newly refinished rotors to correct LRO). This LRO measurement, and the Correctional Plate part number used to correct the LRO, MUST be written/documented on the customer service order hard copy. If no correction is necessary, only the LRO measurement for each rotor serviced needs to be recorded.
Important:
Correction plates can only be used on Hubless rotor design. A correction plate part number can not be used with Hubbed, Trapped or Captured type designed rotors.
Warranty System Documentation - Lateral Run Out (LRO) - REQUIRED
When using any one of the brake labor operations listed in this bulletin, the Lateral Run Out (LRO) measurement (as measured in the "customer service order Documentation - Lateral Run Out" section above) MUST be documented in the technician comments section of the warranty claim.
Customer Service Order Documentation - Explanation of Part Replacement - REQUIRED
If replacement of a brake component is necessary, proper documentation on the customer service order is required. See the following examples:
^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification.
^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper.
TOOL INFORMATION
CORRECTION PLATE PART INFORMATION
Application charts can be viewed on-line at website.
For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be documented in technician comments of the warranty claim and the cost of the plates submiffed as a Net Amount (net item code "M") at cost plus 40%.
Brake Align(R) Run-Out correction Plates are available through the following suppliers:
^ Dealer Equipment and Services at GM Tools
^ Brake Align(R) LLC (U.S. Dealers Only)
* We believe this source and their products to be reliable. There may be additional manufacturers of such products.
General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources.
WARRANTY INFORMATION
For vehicles repaired under warranty, use the table.
* Labor operation H9709 - Brake Burnish should be used to claim the necessary time for cleaning up the braking surfaces for thickness variation pulsation due to lot rot corrosion (refer to Brake Pulsation section of this bulletin for procedure). Thickness Variation Pulsation due to lot rot corrosion occurs when vehicles are not driven for an extended period of time. Therefore, this type of corrosion clean-up is only covered under warranty for vehicles with less than 160 km (100 mi).
Published labor operations include time to check run-out and road test vehicle after repair.
If correcting for LRO, the times for using correction plates are not to exceed 0.2 hr for one side and 0.4 hr for both sides (published as an add condition with the above labor operations as necessary).
WORKSHEET - BRAKE LATHE CALIBRATION
ATTACHMENT FORM - GM BRAKE SERVICE CUSTOMER SERVICE ORDER DOCUMENTATION FOR REQUIRED MEASUREMENTS
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