Inspection item
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remark
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Scratches, rust, saturated lining materials and wear
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- If the vehicle is not driven for a long period of time, sections of the discs that are not in contact with the pads will become rusty, causing noise and shuddering.
- If grooves and scratches resulting from excessive disc wear are not removed prior to installing a new pad assembly, there will be inadequate contact between the disc and the lining (pad) until the pads conform to the disc.
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Run-out
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Excessive run-out of the discs will increase the pedal depression resistance due to piston kick-back.
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Change in thickness (parallelism)
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If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging.
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Inset or warping (flatness)
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Overheating and improper handling while servicing will cause warping or distortion.
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1.Using a micrometer, measure disc thickness at eight positions, approximately 45 degrees apart and 10 mm in from the outer edge of the disc.
Standard value: 28.0 mm
Minimum limit: 26.4 mm
| note |
Thickness variation (at least 8 positions) should not be more than 0.015 mm.
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2.
| caution |
- After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder.
- When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding.
- Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N·m. When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder.
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3.If the disc thickness is less than the limits, replace it with a new one.
If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc.
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1.Remove the brake assembly, and then hold it with wire.
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2.Temporarily install the disc with the hub nut.
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3.Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.
Limit: 0.06 mm
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4.If the brake disc run-out exceeds the limit, correct it as follows:
(1)
Chalk phase marks on the wheel stud and the brake disc, which run-out is excessive as shown.
(2)
Remove the brake disc. Then place a dial gauge as shown, and measure the axial play by pushing and pulling the wheel hub.
Limit: 0 mm
(3)
If the axial play exceeds the limit, disassemble the hub and knuckle assembly to check each part.
(4)
If the axial play does not exceed the limit, dephase the brake disc and secure it. Then recheck the brake disc run-out.
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5.
| caution |
- After a new brake disc is installed, always grind the brake disc with on-the-car type brake lathe. If this step is not carried out, the brake disc run-out exceeds the specified value, resulting in judder.
- When the on-the-car type lathe is used, first install M12 flat washer on the stud bolt in the brake disc side according to the figure, and then install the adapter. If the adapter is installed with M12 flat washer not seated, the brake disc rotor may be deformed, resulting in inaccurate grinding.
- Grind the brake disc with all wheel nuts diagonally and equally tightened to the specified torque 100 N·m. When all numbers of wheel nuts are not used, or the tightening torque is excessive or not equal, the brake disc rotor or drum may be deformed, resulting in judder.
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If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or grind it with the on-the-car type brake lathe ("MAD, DL-8700PF" or equivalent).
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