7/25/2019 Fitment Centre Training Part 4
1/34
rouble Shooting Observations
Inspection of the CALIPERS
What TYPE of Caliper is it?
Are the SLIDE PINS in good
condition?
Does the PISTON move freely in the
Caliper?
Are there CRACKS on the piston or
the Casting?
Are the RETAINING BOLT HEADS
damaged?
Are the MOUNTING POINTS solid?
Light Duty Trouble
Shooting
7/25/2019 Fitment Centre Training Part 4
2/34
Trouble Shooting Observations
Inspection of the DUST SEALS
Slide Pin Seals
Pistons Seals
n Place?
Torn?
Cracked ?
Melted?
Light Duty Trouble
Shooting
7/25/2019 Fitment Centre Training Part 4
3/34
Problem Solving:
ObservationsHydraulic Hoses Leaking
Brake fade or Failure
Excessive Pedal Travel
Vibration or Scuffing
Incorrectly tightened
Cuts from foreign matter
Pipes cracked
Actions:Replace completely
Light Duty Trouble
Shooting
7/25/2019 Fitment Centre Training Part 4
4/34
Trouble ShootingObservations
Inspection of the DISCS Are the discs
VENTILATED or SOLID?
Are the Discs
CRACKED or GROOVED?
Are the Discs Blued
One Side or Both
Are there signs of METAL PICK-UP?
Are there HIGH SPOTS?
Is the Disc WARPED?
Is the Disc in specification for
THICKNESS?
Light Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
5/34
How to measure the disc for wear
The tools required to measurethe disc are the outside caliperand the ruler.
Close the caliper claws on thedisc by turn the adjusting nut take care not to over tightenthe caliper, twist the caliper
and pull it from the disc. Use the ruler to check the gap
between the caliper claws.
Ruler
Outside caliper
Claws
Adjusting nut
7/25/2019 Fitment Centre Training Part 4
6/34
How to check if the disc is warped
or damaged Check the wheel
bearing end float,
adjust to specifications
or replace the bearing.
Use the dial gauge to
check for any disc run-
out which indicates a
warped disc or badly
damaged disc
7/25/2019 Fitment Centre Training Part 4
7/34
Hydraulic systems
BRAKE FLUIDCheck the Brake Fluid
Clear (fluid in good condition)Black (dirty fluid)
Muddy Brown (overheated fluid)
When was the brake fluid last CHANGED?
Black
Muddy brown
Clear
7/25/2019 Fitment Centre Training Part 4
8/34
CATEGORY AAUDIBLE.
ComplaintSqueal - High-pitched noise.
Possible causesDust.
Dirty Pistons and Calipers.
Wheel Bearings worn or badly adjusted.
Discs worn.
Suspension Rubbers Perished.
90% from the rear after front fitment.
Squeal can be defined as a noise that has beenallowed to be transmitted from the source, intothe vehicle body where it is amplified to humanaudible levels.
CATEGORY AAUDIBLE.
ComplaintSqueal - High-pitched noise.
Possible causesDust.
Dirty Pistons and Calipers.
Wheel Bearings worn or badly adjusted.
Discs worn.
Suspension Rubbers Perished.
90% from the rear after front fitment.
Squeal can be defined as a noise that has beenallowed to be transmitted from the source, intothe vehicle body where it is amplified to humanaudible levels.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
9/34
CATEGORY AAUDIBLE
ComplaintRattle - Metallic rattle,clunking
Possible causes
Pads not fitted correctly
Anti Rattle Plates Omitted
Anti Rattle Springs
Omitted
Bent
Inherent to Vehicle
CATEGORY AAUDIBLE
ComplaintRattle - Metallic rattle,clunking
Possible causes
Pads not fitted correctly
Anti Rattle Plates Omitted
Anti Rattle Springs
Omitted
Bent
Inherent to Vehicle
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
10/34
CATEGORY AAUDIBLE
ComplaintGrinding - Heavy metal grinding, scraping noise
Possible causes
Disc Pads BACK TO FRONT
Friction material completely worn out
CATEGORY AAUDIBLE
ComplaintGrinding - Heavy metal grinding, scraping noise
Possible causes
Disc Pads BACK TO FRONT
Friction material completely worn out
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
11/34
Category BPhysical.
ComplaintLock-up - Brakes grab & lock-up,
Possible cause
Air in Hydraulic System.
Foreign objects.
Wrong co-efficient of friction.
Load sensor valve not working or not
set-up.
Narrower Tyres fitted.
Suspension raised.
Category BPhysical.
ComplaintLock-up - Brakes grab & lock-up,
Possible cause
Air in Hydraulic System.
Foreign objects.
Wrong co-efficient of friction.
Load sensor valve not working or not
set-up.
Narrower Tyres fitted.
Suspension raised.
Light Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
12/34
Category BPhysical
Complaint
Judder - Rhythmic, oscillatingshudder, also noisy.
Possible causes
High spots on Discs
Caliper seizure
Slide Pins Bent
Discs Warped
Category BPhysical
Complaint
Judder - Rhythmic, oscillatingshudder, also noisy.
Possible causes
High spots on Discs
Caliper seizure
Slide Pins Bent
Discs Warped
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
13/34
Category BPhysical.
Complaint
Snatching - Brakes grab& let go.
Possible causes
Caliper action not
smooth.
Brake fluid
contaminated.
Category BPhysical.
Complaint
Snatching - Brakes grab& let go.
Possible causes
Caliper action not
smooth.
Brake fluid
contaminated.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
14/34
Category C Performance.ComplaintFade - Spongy feel to pedal, resulting
in pedal fade.
Possible causes
Hydraulic Blockage.
Overloading.
High Speed driving and short
braking.
Modified vehicle.
Category C Performance.ComplaintFade - Spongy feel to pedal, resulting
in pedal fade.
Possible causes
Hydraulic Blockage.
Overloading.
High Speed driving and short
braking.
Modified vehicle.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
15/34
Category C Performance.Complaint
Brake Fade - Solid brake pedal, insufficientstopping power.
Possible causes
Contaminated Brake Fluid.
Sticking/Seized Calipers.
Category C Performance.Complaint
Brake Fade - Solid brake pedal, insufficientstopping power.
Possible causes
Contaminated Brake Fluid.
Sticking/Seized Calipers.
Light Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
16/34
CategoryC
Performance.
ComplaintDead Pedal - Dead non -
progressive feel to pedal.
Possible causes
Caliper Seized.
Master Cylinder Blocked.Brake Pipes Blocked.
Backing Plates Bent.
CategoryC
Performance.
ComplaintDead Pedal - Dead non -
progressive feel to pedal.
Possible causes
Caliper Seized.
Master Cylinder Blocked.Brake Pipes Blocked.
Backing Plates Bent.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
17/34
Light duty trouble shooting
Category DSubliminal
ComplaintHesitation a short delay before thebrakes take
Possible causes
Air in hydraulic system.
Insecure brake mountings.
Pedal free play excessive.
7/25/2019 Fitment Centre Training Part 4
18/34
Problem Solving:Observations
Foreign objects.
Chips and/or Gouges on the
friction material.
Discs Badly scoured.
Objects picked-up by tyres and
thrown into the caliper.
ACTION:Clean out caliper and replace brake
pads.
Problem Solving:Observations
Foreign objects.
Chips and/or Gouges on the
friction material.
Discs Badly scoured.
Objects picked-up by tyres and
thrown into the caliper.
ACTION:Clean out caliper and replace brake
pads.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
19/34
Problem Solving:Observations
Discs Warped.Pedal Jump.
Judder.
Steering Pull.
Poorly Skimmed.
Over Heated.
Actions:Replace the Discs and the pads
as well as the Brake Fluid.
Problem Solving:Observations
Discs Warped.Pedal Jump.
Judder.
Steering Pull.
Poorly Skimmed.
Over Heated.
Actions:Replace the Discs and the pads
as well as the Brake Fluid.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
20/34
Problem Solving:Observations
Slide Pins Bent /Worn.
Caliper Seizure.
Sticky Caliper Movement.
Judder or Squeal.
Steering Pull.
Not correctly tightened.
Forced at some stage.
Actions:Remove and replace the pins and seals.
Check for other damage.
Problem Solving:Observations
Slide Pins Bent /Worn.
Caliper Seizure.
Sticky Caliper Movement.
Judder or Squeal.
Steering Pull.
Not correctly tightened.
Forced at some stage.
Actions:Remove and replace the pins and seals.
Check for other damage.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
21/34
Problem Solving:Observations
One pad worn
High spots
Steering pull
Slide pins coated with old lubricant
& brake dust
Dust covers worn or melted
ACTIONSOverhaul Caliper.
Replace all Seals and Brake Fluid.
Lubricate slide pins with CV grease.
Problem Solving:Observations
One pad worn
High spots
Steering pull
Slide pins coated with old lubricant
& brake dust
Dust covers worn or melted
ACTIONSOverhaul Caliper.
Replace all Seals and Brake Fluid.
Lubricate slide pins with CV grease.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
22/34
Problem Solving:
Observation Disc pads back to frontGraunching
Grinding
Lack of Knowledge
Action:Training required
Replace pads and fit correctly
Problem Solving:
Observation Disc pads back to frontGraunching
Grinding
Lack of Knowledge
Action:Training required
Replace pads and fit correctly
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
23/34
Problem Solving:Observations
Pistons SeizedHigh pad wear rate
Disc warp
Disc discoloration
Brake fade
Calipers never cleaned or
overhauled
Dust covers torn, melted or
missing
Poor maintenance
Actions: Overhaul CalipersReplace the seals andthe brake fluid
Problem Solving:Observations
Pistons SeizedHigh pad wear rate
Disc warp
Disc discoloration
Brake fade
Calipers never cleaned or
overhauled
Dust covers torn, melted or
missing
Poor maintenance
Actions: Overhaul CalipersReplace the seals andthe brake fluid
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
24/34
Problem Solving: Observationsand Consequences
Dust Covers TornPiston seizure
Brake fluid leak
Caliper action not smooth
Brake fluid contaminated
Dust covers aged and
perished
Poor fitting proceduresForeign objects
Actions:Remove and replace
Problem Solving: Observationsand Consequences
Dust Covers TornPiston seizure
Brake fluid leak
Caliper action not smooth
Brake fluid contaminated
Dust covers aged and
perished
Poor fitting proceduresForeign objects
Actions:Remove and replace
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
25/34
Problem Solving:
ObservationsHydraulic Hoses LeakingBrake fade or Failure
Excessive Pedal Travel
Vibration or Scuffing
Incorrectly tightened
Cuts from foreign matter
Actions:Replace completely
Problem Solving:
ObservationsHydraulic Hoses LeakingBrake fade or Failure
Excessive Pedal Travel
Vibration or Scuffing
Incorrectly tightened
Cuts from foreign matter
Actions:Replace completely
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
26/34
Problem Solving:
ObservationsMetal Pick-up
Discs badly scored
Pads show traces of metal
splinters (check with magnet)
Metallurgical reaction of disc
material to disc pads
Actions:Replace Discs and Disc Pads.
Problem Solving:
ObservationsMetal Pick-up
Discs badly scored
Pads show traces of metal
splinters (check with magnet)
Metallurgical reaction of disc
material to disc pads
Actions:Replace Discs and Disc Pads.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
27/34
Problem Solving:Observations
High Spots on dics
Points of discoloration at a
radius usually equally
spaced
Calipers not functioning
properly
Discs not skimmed correctly
Actions:
Check Calipers
Re-skim Discs or replace Discs
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
28/34
Problem Solving:Observations
Discs Over Skimmed (too thin).
Warping.
Cracking.
Disintegration.
Lack of observation by skimmer.
Poor vehicle management.
Action:
Replace Discs.
Problem Solving:Observations
Discs Over Skimmed (too thin).
Warping.
Cracking.
Disintegration.
Lack of observation by skimmer.
Poor vehicle management.
Action:
Replace Discs.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
29/34
Problem Solving:Observations
Pads not fitted correctly.Backing plates bent.
Pads badly worn (tapered).
Lack of training.
Poor workmanship.
Actions:
Training requiredReplace disc pads correctly.
Problem Solving:Observations
Pads not fitted correctly.Backing plates bent.
Pads badly worn (tapered).
Lack of training.
Poor workmanship.
Actions:
Training requiredReplace disc pads correctly.
Light Duty Trouble ShootingLight Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
30/34
Light duty trouble shooting
Problem solving: Observation
Cracked padsPads flexingPads not free to move
Piston bent in back plate
Actions:
Replace pad set
7/25/2019 Fitment Centre Training Part 4
31/34
Problem Solving:
ObservationsIncorrect pads fitted
Damaged pads
Friction material lose
from back plate
Actions:
Training requiredReplace disc pads
correctly
Light Duty Trouble Shooting
7/25/2019 Fitment Centre Training Part 4
32/34
Light Duty Trouble Shooting
Problem Solving:Observations
Pads surface glazed.High temperature at
short durations
Actions:
Correct by normal use
7/25/2019 Fitment Centre Training Part 4
33/34
Light Duty Trouble ShootingProblem Solving:
ObservationsDenaturing.
Whitish outer edge.
(denaturing)
Excessive temperature due to
intensive use or dragging
Actions:If minor damage pads can be
re-used but recommendreplacement
7/25/2019 Fitment Centre Training Part 4
34/34
Top Related