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Test Procedure

WARNING: This page is about a different car, the 2003 Chevrolet SSR. However, it is still accessible from the selected car via links, so may be relevant.
  1. Were you sent here from SYMPTOM LIST  under SYMPTOMS - HYDRAULIC BRAKE in TROUBLE SHOOTING? If so, go to next step. If not, see DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKES  under TROUBLE SHOOTING.
  2. Visually inspect the disc brake pads for the following conditions:
    • Lining Thickness Below Specifications
    • Uneven And/Or Abnormal Wear - Edge-To-Edge And/Or Side-To-Side
    • Evidence Of Contamination From An External Substance
    • Looseness Or Damage - Including Pad Hardware
    Did you find any conditions to indicate a concern with any of the front and/or rear disc brake pads? If so, go to next step. If not, go to step  12 .
  3. Are any of the front and/or rear disc brake pads contaminated? If so, go to step  8 . If not, go to next step.
  4. Are any of the front and/or rear disc brake pads worn unevenly? If so, go to step  7 . If not, go to next step.
  5. Are any of the front and/or rear disc brake pads and/or pad hardware loose or damaged? If so, go to step  7 . If not, go to next step.
  6. Remove and inspect the worn disc brake pads for glazing, looseness, heat spots or damage. Replace the worn disc brake pads as a complete axle set. See BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the inspection and replacement? If so, go to step  12 .
    7. NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
  7. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. See BRAKE CALIPERS  under REMOVAL & INSTALLATION. DO NOT disconnect the hydraulic brake flex hoses from the calipers. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions:
    • Loose, bent, cracked, or damaged caliper mounting bracket.
    • Binding or seized hardware.
    • Worn and damaged or missing hardware components.
    Replace components as required.
    • Brake Caliper Bracket Replacement - Front And Rear
    • Disc Brake Hardware Replacement - Front And Rear
    See REMOVAL & INSTALLATION  for proper procedures. Did you complete the inspection and replacement? If so, go to step  12 .
  8. Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak. Replace any components found to be leaking brake fluid.
    • Brake Caliper Overhaul - Front And Rear
    • Brake Caliper Replacement - Front And Rear
    • Brake Hose Replacement - Front And Rear
    • Brake Pipe Replacement - Front And Rear
    See REMOVAL & INSTALLATION  and OVERHAUL  for proper procedures. Did you find and correct the source of the leak causing contamination of the pads? If so, go to step  11 . If not, go to next step.
  9. Inspect the wheel drive shaft outer seals for damage and evidence of a grease leak. Inspect the rear axle seals for damage and evidence of a lubricant leak. Replace any wheel drive shaft seal that is found to be leaking grease which may be the source of the contamination to the pads. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Did you find and correct the source of the leak causing contamination of the pads? If so, go to step  11 . If not, go to next step.
  10. Inspect the following systems for damage and evidence of an external fluid leak. Replace any components found to be leaking fluid which may be the source of the contamination to the pads. Refer to the following procedures:
    • See appropriate DIAGNOSTIC STARTING POINT - POWER STEERING SYSTEM in POWER STEERING SYSTEM article in STEERING.
    • See appropriate DIAGNOSTIC STARTING POINT - ENGINE CONTROLS in ENGINE MECHANICAL - 5.3L article in ENGINES.
    • See appropriate DIAGNOSTIC STARTING POINT - AUTOMATIC TRANSMISSION in AUTOMATIC TRANSMISSION - 4L60-E article in TRANSMISSIONS.
    Did you find and correct the source of the leak causing contamination of the pads? If so, go to next step.
    11. NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
  11. Clean the remaining disc brake system components to remove any traces of the contaminant. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. DO NOT disconnect the hydraulic brake flex hoses from the calipers. Inspect the disc brake caliper mounting/sliding hardware for the following conditions
    • Binding or seized hardware.
    • Distorted, worn, damaged or missing hardware components.
    Replace the caliper mounting/sliding hardware components as required. See DISC BRAKE HARDWARE  under REMOVAL & INSTALLATION. Replace the contaminated disc brake pads as a complete axle set. See BRAKE PADS  under REMOVAL & INSTALLATION. Did you complete the cleaning, inspection and replacement? If so, go to next step.
  12. Visually inspect each of the rear disc brake rotor shields/backing plates for evidence of contact with the brake rotors. Are any of the rear brake rotor shields/backing plates contacting the brake rotors? If so, go to next step. If not, go to step  14 .
  13. Repair or replace the rear disc brake rotor shields/backing plates as required. See DISC BRAKE SPLASH SHIELD - FRONT  and DISC BRAKE BACKING PLATE - REAR  under REMOVAL & INSTALLATION. Did you complete the repair or replacement? If so, go to next step.
  14. Check the thickness of each of the disc brake rotors. Make a determination for each brake rotor if the rotor can be refinished and remain above the minimum requirements. See BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTION. Does the disc brake rotor meet the minimum requirements for refinishing? If so, go to next step. If not, go to step  17 .
  15. Inspect each of the disc brake rotors for the following surface and wear conditions:

    Braking Surface Conditions

    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.

    Braking Surface Wear Conditions

    • Deep or excessive scoring beyond maximum acceptable level.
    • Lateral runout beyond maximum acceptable level.
    • Thickness variation beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. If the brake rotor exhibits any of the following conditions, it requires refinishing.
    • Rotor exhibits one or more of the Braking Surface Conditions listed previously.
    • Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions listed previously.
    Does the brake rotor require refinishing? If so, go to next step. If not, go to step  20 .
  16. Refinish the brake rotor. See ROTOR REFINISHING  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Inspect the brake rotor thickness. See BRAKE ROTOR THICKNESS MEASUREMENT  in DISC BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Were you able to refinish the brake rotor within the minimum requirements? If so, go to step  20 . If not, go to step  19 .
  17. Is the brake rotor at or below the discard requirements? If so, go to step  19 . If not, go to next step.
  18. Inspect each of the disc brake rotors for the following surface and wear conditions:

    Braking Surface Conditions

    • Heavy rust and/or pitting.
    • Cracks and/or heat spots.
    • Excessive blueing discoloration.

    Braking Surface Wear Conditions

    • Deep or excessive scoring beyond maximum acceptable level.
    • Lateral runout beyond maximum acceptable level.
    • Thickness variation beyond maximum acceptable level.
    Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. If the brake rotor exhibits any of the following conditions, it requires refinishing.
    • Rotor exhibits one or more of the Braking Surface Conditions listed previously.
    • Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions listed previously.
    Does the brake rotor require refinishing? If so, go to next step. If not, go to step  20 .
  19. Replace the brake rotor. See BRAKE ROTORS  under REMOVAL & INSTALLATION. Did you complete the replacement? If so, go to next step.
  20. Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? If so, then system is okay. If system is not okay, go to step  2 .
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