Brakes - Disc Brake Warranty Service And Procedures: Overview
INFORMATIONBulletin No.: 05-05-22-002E
Date: July 16, 2009
Subject: Disc Brake Warranty Service and Procedures - Lateral Runout (LRO), Rotor Pulsation, Pads, Wear, Noise, Refinish, Clean-up, Corrosion, Squeak, Grind, Groan
Models:
1999-2010 Saturn Vehicles (U.S. Only)
Supercede:
This bulletin is being revised to include the 2010 model year and to update the Warranty Information. Please discard Corporate Bulletin Number 05-05-22-002D (Section 05 - Brakes).
Important
- Saturn retailers in Canada should refer to Corporate Bulletin Number 00-05-22-002L.
- For all warranty brake service, the procedures in this bulletin must be followed.
- PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE.
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, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index.
The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service.
1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) - determine rotor clean-up/refinish/replace
2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel
3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order)
Important
If you are consistently measuring high LRO after rotor refinishing, verify lathe equipment is properly calibrated.
4. After brake pad replacement and/or rotor clean-up/refinish/replace, measure and document Lateral Run Out [LRO]-- (REQUIRED on the Repair Order. If post-service Lateral Run Out (LRO) measures above specification, maximum 0.050 mm (0.002 in) **, Correct for LRO using Brake Align(R) Plate (part number REQUIRED on Repair Order). For more information and the Brake Align(R) application chart, refer to TSB 01-05-23-001B.
5. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence -- wheel lug nuts.
* The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec.
**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
Reference:
***CUSTOMER SERVICE ORDER/WARRANTY CLAIM REQUIRED DOCUMENTATION
Important
When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), 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) shown in 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 (except for H0192/H0202 - Brake Drum Refinishing and H9709 - Brake Burnish), 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(R) 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 (except for H0192/H0202 - Brake Drum Refinishing and H9709 - Brake Burnish), 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.
Disclaimer