Canada - Brakes - Front Brake Rattle Squeak Noise

Bulletin
TSB2994

Issue Date
April 24, 2008

Market
Canada

Title
Front Brake Rattle/Squeak Noise

Component
BRAKES

Models
'03-'08 Corolla & Matrix

TSB UPDATE NOTICE
The information contained in this TSB supersedes TSB2815. TSB2815 is now obsolete and should be discarded.

INTRODUCTION:

Some customers may experience a front brake rattle type noise when the car is traveling over bumps. Updated front disc brake cylinder [caliper] mountings and disc brake pad support plates are available to improve this condition.






APPLICABLE VEHICLES:

PRODUCTION CHANCE INFORMATION:







This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.






WARRANTY:






PARTS INFORMATION:






COMPONENTS:

REPAIR PROCEDURE:

1. Conduct a road test to verify the noise condition - front brake rattle noise will occur when the front tire runs over a depression in the road.
2. Remove and replace the front disc brake pad support plates (2 per each caliper].

NOTE
The procedures listed below are for one side and should be used for both the RH and LH side.

A. Remove the front wheel.
B. Remove the caliper by holding the front disc brake slide pin and removing the 2 bolts.
C. Remove the 2 front brake pads from the front disc brake cylinder mounting.
D. Remove the anti-squeal shims and the pad wear indicator plates from each pad.
E. Remove the 2 front disc brake pad support plates from the cylinder mounting.
F. Remove the front disc brake cylinder mounting by removing the 2 bolts.
G. Install the NEW disc brake cylinder mounting plate with the 2 bolts.
Torque: 107 N-m (1089 kgf-cm, 79 ft-lbf)

H. Install the 2 NEW disc brake pad support plates.
Apply disc brake grease to the back of the brake pad support plate.

I. Install the front anti-squeal shims.







(1) Apply disc brake grease to the anti-squeal shims.

NOTE
- When replacing worn pads, the anti-squeal shims MUST be replaced together with the pads.
- Make sure to install the shims in the correct positions and directions.
- Apply a thin layer of disc brake grease to the area that contacts the anti-squeal shim.
- Disc brake grease can come out slightly from the area where the anti-squeal shim is installed. Be sure to wipe off any excessive grease to avoid pad contamination.
- Make sure that disc brake grease is NOT applied onto the lining surface.

(2) Install the anti-squeal shims and the pad wear indicators to each pad.

NOTE
Make sure to install the pad wear indicators in the correct positions and directions.

J. Install the 2 front brake pads with anti-squeal shims to the disc brake cylinder mounting. Apply a small amount of the disc brake grease (1-2 mm [0.04 - 0.08 in.] thick) to the areas shown in Figure 2.

NOTE
Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.

K. Install the caliper with the 2 bolts.
Torque: 34 N-m (350 kgf-cm, 25 ft-lbf)

L. Install the front wheel.
Torque: 103 N-m (1050 kgf-cm, 76 ft-lbf)

3. Road test the vehicle to confirm the front brake rattle noise is NO longer present.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.