Brake Rotor/Disc: Service and Repair
STANDARD PROCEDURE - BRAKE ROTOR MACHININGNOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen.
Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action.
On-Car Brake Lathe:
If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe, or replaced. The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing.
Minimum Brake Rotor Thickness Markings (Typical):
NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor or stamped into the hat section. Minimum thickness specifications can also be found in specifications.
Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination.
When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required.
Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be found in specifications.
REMOVAL- BRAKE ROTOR (FRONT)
1. Raise the vehicle.
2. Remove the front tire and wheel assembly.
3. Remove the front disc brake caliper assembly from the brake rotor and store it out of the way.
4. Remove the clips retaining the brake rotor.
5. Remove the brake rotor by pulling it straight off the wheel mounting studs.
REMOVAL- BRAKE ROTOR (REAR)
1. Raise the vehicle.
2. Remove the rear tire and wheel assembly.
3. Remove the rear disc brake caliper assembly from the brake rotor and store it out of the way.
4. Remove any clips retaining the brake rotor.
5. Remove the brake rotor by pulling it straight off the wheel mounting studs.
INSTALLATION - BRAKE ROTOR (FRONT)
1. Install the brake rotor over the wheel mounting studs and onto the hub.
2. Install the front disc brake caliper. It may be necessary to retract the brake caliper piston back into the caliper to fit the shoes onto the rotor.
3. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.).
4. Lower the vehicle.
5. Pump the brake pedal before moving the vehicle to set the brake shoes to the brake rotor.
INSTALLATION - BRAKE ROTOR (REAR)
NOTE: Inspect the disc brake shoes and parking brake shoes before brake rotor installation.
1. Install the rear brake rotor over the wheel mounting studs and onto the hub.
2. Install rear disc brake caliper.
3. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.).
4. Adjust the parking brake shoes as necessary.
5. Lower the vehicle.
6. Pump the brake pedal before moving the vehicle to set the brake shoes to the brake rotor.