Procedures

Brake Disc Machining

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

General Procedure

NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing the lathe.

NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the lathe is not self-adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0 mm (0 in). The maximum indicated runout should be no more than 0.05 mm (0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final brake disc runout will be within specification and a runout measurement is not necessary after machining.

NOTE: Do not machine new brake discs.

NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specification.

1. Remove the wheel and tire. REFER to Wheel and Tire .

2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur.

NOTE: It is not necessary to disconnect the brake tube from the brake caliper.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as required.

- Support the brake caliper using mechanic's wire.

3. Install the hub adapter using:

- four wheel nuts on a 4, 7 or 8-stud wheel hub.
- five wheel nuts on a 5 or 10-stud wheel hub.
- six wheel nuts on a 6-stud wheel hub.

4. Install the cutting lathe.

5. If the lathe is not self-adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0 mm (0 in). The maximum indicated runout should be no more than 0.05 mm (0.002 in).

6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.

7. NOTE: The depth of the cut should be between 0.1 mm (0.0039 in) and 0.4 mm (0.0157 in). Lighter cuts cause the bit to heat up and wear faster. Heavier cuts cause poor brake disc surface finish.
Machine the brake disc.

8. Remove the lathe and the silencer.

9. Remove the wheel nuts and hub adapter.

10. Remove the metal shavings.

11. Measure the brake disc thickness.

- If the measurement is below the minimum specification, install a new brake disc. REFER to General Specifications for front disc brakes or REFER to General Specifications for rear disc brakes.

12. NOTE: It is not required to install new brake pads if friction material is within specifications. REFER to General Specifications .
Position the brake caliper or brake caliper and anchor plate assembly.

- Install the bolts.
- For fastener torque specifications, REFER to Torque Specifications for front disc brakes or REFER to Torque Specifications for rear disc brakes.

13. Install the wheel and tire. REFER to Wheel and Tire .