For 1990-2009 cars

### Test Description

The numbers below refer to the step numbers on the diagnostic table:

1. Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.

2. Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.

3. Disc brake shields that come in contact with disc brake rotors may cause brake system noise.

Step | Action | Yes | No
--- | --- | --- | ---
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.
1 | Were you sent here from a Brake Symptom Table? | Go to Step 2 | Go to Diagnostic Starting Point - Hydraulic Brakes
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?

Go to Step 3

Go to Step 12

3 | Are any of the front disc brake pads contaminated? | Go to Step 8 | Go to Step 4
4 | Are any of the front disc brake pads worn unevenly? | Go to Step 7 | Go to Step 5
5 | Are any of the front disc brake pads and/or pad hardware loose or damaged? | Go to Step 7 | Go to Step 6
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. Refer to Brake Pads Replacement in Disc Brakes.

Did you complete the inspection and replacement?

Go to Step 12

--

7 |

Notice: 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.

1. 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. Refer to Brake Caliper Replacement in Disc Brakes.
2. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions:

Refer to Disc Brake Mounting and Hardware Inspection in Disc Brakes.

• | Loose, bent, cracked, or damaged caliper mounting bracket

• | Binding or seized hardware

• | Worn, damaged or missing hardware components

3. Replace the caliper bracket, if necessary. Refer to Brake Caliper Bracket Replacement in Disc Brakes.
4. Replace the unevenly-worn, loose or damaged disc brake pads and/or hardware, if necessary. Refer to Brake Pads Replacement in Disc Brakes.

Did you complete the inspection and replacement?

Go to Step 12

--

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.

Refer to the following procedures as required:

• | Brake Caliper Overhaul or Brake Caliper Replacement in Disc Brakes

• | 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

9 |

1. Inspect the wheel drive shaft outer seals or boots for damage and evidence of a grease leak.
2. Replace any wheel drive shaft seal or boot that is found to be leaking grease which may be the source of the contamination to the pads. Refer to Wheel Drive Shaft Replacement - Left Side or to Wheel Drive Shaft Replacement - Right Side in Wheel Drive Shafts.

Did you find and correct the source of the leak causing contamination of the pads?

Go to Step 11

Go to Step 10

10 |

1. Inspect the for damage and evidence of an external fluid leak.
2. Replace any components found to be leaking fluid which may be the source of the contamination to the pads.

Refer to the following procedures:

• | Diagnostic Starting Point - Power Steering System in Power Steering System

• | Diagnostic Starting Point - Engine Mechanical in Engine Mechanical - 1.6L

• | Diagnostic Starting Point - Engine Mechanical in Engine Mechanical - 2.0L

• | Diagnostic Starting Point - Engine Mechanical in Engine Mechanical - 2.5L

Did you find and correct the source of the leak causing contamination of the pads?

Go to Step 11

--

11 |

1. Clean the remaining disc brake system components to remove any traces of the contaminant.

Notice: 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.

2. 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. Refer to Brake Caliper Replacement in Disc Brakes.
3. Inspect the disc brake caliper mounting/sliding hardware for the following conditions:

Refer to Disc Brake Mounting and Hardware Inspection in Disc Brakes.

• | Binding or seized hardware

• | Distorted, worn, damaged or missing hardware components

4. Replace the disc brake pads and/or the caliper mounting/sliding hardware components, if necessary. Refer to Brake Pads Replacement in Disc Brakes.

Did you complete the cleaning, inspection and replacement?

Go to Step 12

--

12 | Visually inspect each of the disc brake rotor shields/backing plates, if equipped, for evidence of contact with the brake rotors. Are any of the brake rotor shields/backing plates contacting the brake rotors? | Go to Step 13 | Go to Step 14
13 | Repair or replace the disc brake rotor shield/backing plate as required. Refer to Front Brake Shield Replacement in Disc Brakes. Did you complete the repair or replacement? | Go to Step 14 | --
14 |

1. Check the thickness of each of the disc brake rotors.

Important: 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.

Refer to Brake Rotor Thickness Measurement in Disc Brakes.

Does the disc brake rotor meet the minimum requirements for REFINISHING?

Go to Step 15

Go to Step 17

15 |

1. Inspect each of the disc brake rotors for the following surface and wear conditions:

Refer to Brake Rotor Surface and Wear Inspection in Disc Brakes.

• | Braking surface conditions

- | Heavy rust and/or pitting

- | Cracks and/or heat spots

- | Excessive blueing discoloration

• | Braking surface wear conditions

- | Deep or excessive scoring beyond maximum acceptable level

- | Lateral runout beyond maximum acceptable level

- | Thickness variation beyond maximum acceptable level

Important: 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.

If the brake rotor exhibits any of the following conditions, it requires refinishing.

• | Rotor exhibits one or more of the Braking Surface Conditions listed previously

• | Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions listed previously

Does the brake rotor require REFINISHING?

Go to Step 16

Go to Step 20

16 |

1. Refinish the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.
2. Inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement in Disc Brakes.

Were you able to REFINISH the brake rotor within the minimum requirements?

Go to Step 20

Go to Step 19

17 | Is the brake rotor at or below the DISCARD requirements? | Go to Step 19 | Go to Step 18
18 |

1. Inspect each of the disc brake rotors for the following surface and wear conditions:

Refer to Brake Rotor Surface and Wear Inspection in Disc Brakes.

• | Braking surface conditions

- | Heavy rust and/or pitting

- | Cracks and/or heat spots

- | Excessive blueing discoloration

• | Braking surface wear conditions

- | Deep or excessive scoring beyond maximum acceptable level

- | Lateral runout beyond maximum acceptable level

- | Thickness variation beyond maximum acceptable level

Important: 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.

If a brake rotor exhibits any of the following conditions, it requires refinishing.

• | Rotor exhibits one or more of the Braking Surface Conditions listed previously

• | Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions listed previously

Does the brake rotor require REPLACEMENT?

Go to Step 19

Go to Step 20

19 | Replace the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes. Did you complete the replacement? | Go to Step 20 | --
20 | Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? | Disc Brake System OK Return to Symptom Table | --