Académique Documents
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June 2014
MAGAZINE
Import Insights
46
22
30
Publication
CONTENTS
22
30
46
Diagnostic Solutions
Tech Feature
Saab Feature
Managing Editor
Chris Crowell, ext. 268
ccrowell@babcox.com
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kgifford@babcox.com
Circulation Manager
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Editor
Mary DellaValle, ext. 221
mdellavalle@babcox.com
Technical Editor
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lcarley256@aol.com
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Import-Car.com
DEPARTMENTS
Columns
4 Editors Notebook
Contributing Writers
Bob Dowie, Village Auto Works, Chester, NY
6 News Update
18 Gonzos Toolbox
38 Tech Update:
Fuel System FAQs
52
Publication
38
TPMS Update:
64 Classifieds
68 Import Insights: VW
58
68
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Bill Babcox
bbabcox@babcox.com
Vice President/
Chief Financial Officer
Greg Cira
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Vice President/
Group Publisher
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Controller
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bscheetz@babcox.com
In Memoriam
Founder of
Babcox Publications
Edward S. Babcox
(1885-1970)
Chairman
Tom B. Babcox
(1919-1995)
[ EditorsNotebook
By Mary DellaValle|EDITOR
2014
Automotive Service Excellence
(ASE) has declared June 9-15 as
National Automotive Service
Professionals Week.
ASE created National Automotive Service Professionals
Week to recognize the men and
women who service and maintain the highly complex vehicles
upon which we depend for our
daily transportation, said Tim
Zilke, ASE president and CEO.
The training and education
necessary to properly diagnose
and repair todays sophisticated
vehicle fleet requires a significant level of knowledge, skill
and dedication, and ASE is
proud to help recognize these
individuals for their commitment to their customers and
their profession.
Along with ASE, we applaud
your past, present and future
commitment to professional
automotive service. You are the
driving force in service excellence
that keeps America running. IC
[ NewsUpdate
Mitchell 1 to Expand Shop
Management Training with
Super Workshop
Mitchell 1 will hold an expanded Shop Management Super Workshop July 17-19 in San Diego
at the Hotel Salomar. The training workshop is
designed for those who have previously established competence using shop management software and now want to learn more advanced
capabilities, better methods and shortcuts.
Federated Membership
Names Standard Motor
Products Outstanding
Vendor of the Year
[ NewsUpdate
Federal-Mogul Vehicle
Components Division Renamed
Federal-Mogul Motorparts
Federal-Mogul Holdings Corp. announced the next step in its ongoing strategy to drive the global growth of its premium products
and leading brands. Effective immediately, the companys Vehicle
Components division will be renamed Federal-Mogul Motorparts.
Federal-Mogul Motorparts is a leading provider of premium
brands, including MOOG, Fel-Pro, Champion, Wagner, ANCO and
Ferodo to the global aftermarket. Federal-Mogul Motorparts also
provides high-quality vehicle braking, chassis and wiper components to global original equipment manufacturers.
For more than a century, we have remained focused on providing
the highest-quality components across each of the product
categories and regions we serve. Vehicle manufacturers recognize
this, as our friction products are found on seven of the top 10 vehicle
models in Europe, and the best-selling vehicle in North America,
said Daniel Ninivaggi, CEO of Federal-Mogul Motorparts, and coCEO of Federal-Mogul Holdings Corp.
The new Federal-Mogul Motorparts name and logo will be rolled
out globally effective immediately, leading into new marketing
campaigns for its product brands.
[ NewsUpdate
Raybestos Rattlesnake
Sweepstakes Winner
Receives His Ride
Not even heavy rain and winds could dampen the
festive mood at Automotive Electric Distributors
(AED) in Vancouver, WA, on May 9, the day that
David Cramer received the keys to his custom
2014 Raybestos Rattlesnake Toyota Tundra.
Cramer, a property manager with Ross Pacific
Management in Vancouver, WA, took delivery of
his enviable ride in the presence of his mother,
father and a large group of AED staff members.
[ NewsUpdate
WORLDPAC Hosts Third Supplier & Training EXPO
Fulfills Mission of Leading Through Education
By Mary DellaValle
With a sharp focus on supporting its
customers through specialized training, WORLDPAC held its third
Supplier & Training EXPO, May 15-18
at the Marriott World Center in
Orlando, FL. Fulfilling the theme,
Leading Through Education, more
than 500 hours of training was conducted over the three-day event.
Business owners and technicians
numbering 1,400 traveled from near
and far from 45 states, Canada and
even Puerto Rico to partake in the
world-class training for which
WORLDPAC is known. That number is
up from 1,000 attendees at its second
event in 2012. A customized lineup of
120 instructor-led technical training
sessions and business-management
classes were offered, also significantly
up from 75 classes in 2012.
With technology accelerating at
every turn, so too has the need for
advanced technical training so business owners can meet the service and
repair challenges on an increasingly
sophisticated vehicle fleet. Thats why
many WORLDPAC customers closed
their business on Friday to attend the
event, realizing the value of being a
part of something bigger that will pay
dividends in shop productivity and
profitability. Two-thirds of the owners
and techs were first-time attendees,
and the overall sentiment was how
could they afford not
12
to be there.
Many business owners said how
fantastic it is that WORLDPAC would
do this for us, said Mario Recchia,
WORLDPACs senior vice president
marketing, who added, We believe
in education, but if they dont come,
the event wont happen. Theyre
making an investment in their time.
Focusing on the customer is an
overused phrase, but its really evident here from the top downall of
our senior management is here,
continued Recchia.
WORLDPAC customizes topics that
are most suited to its customers
needs, aimed at helping them better
diagnose and service late-model vehicles, more of which they are adding
to their broadening service portfolio.
Serious about the high-level of training offered, the classes are conducted
by some of the industrys most
respected instructors, and includes
many from the WORLDPAC Training
Institute (WTI) and its supplier community, as well as OEM suppliers like
ZF, Denso, Bosch and Delphi.
The vehicle-specific training is
complemented by business-management courses, which are often the
first to sell out. Training and hiring
are our customers two most pressing challenges, explained Recchia,
so our business-related classes are
very popular. WORLDPAC is also
[ NewsUpdate
MAHLE Awarded Polk Inventory
Efficiency Award, Presented by
IHS Automotive
MAHLE Aftermarket Inc. was presented with the Polk Inventory Efficiency Award from IHS Automotive during an awards ceremony at the
Global Automotive Aftermarket Symposium (GAAS), held recently in
Chicago. Ted Hughes, marketing manager, and Chris Booth, supply
chain coordinator North America, were on hand to accept the
award.
The award, now in its 10th
year, recognizes members of
the automotive aftermarket
for their efforts toward inventory efficiency and process
improvement within their
organizations.
Honored with the award in
the manufacturer category,
MAHLE Aftermarket Inc. was
recognized for the implementation of a systematic approach to managing its product portfolio, using vehicles in operation (VIO) data to
prioritize trends and new coverage areas, while customizing inventory
based on parts demand and consumption.
14
[ GonzosToolbox
Recalling
18
[ GonzosToolbox
a chance to turn off the laptop
and open the toolbox. These jobs
restore both the customers
vehicle and some of my old,
almost forgotten, mechanical
abilities.
Those jobs where youve wres-
20
[ DiagnosticSolutions
STEERING/ALIGNMENT
By Gary Goms, Import Specialist Contributor
Mazda6
CASE STUDY
22
[ DiagnosticSolutions
STEERING/ALIGNMENT
24
[ DiagnosticSolutions
STEERING/ALIGNMENT
26
RECOMMENDATIONS
AND THE REPAIR
I responded to the help request
only by properly qualifying my
comments. Clearly, Im not the
person operating the alignment
machine and Im certainly not
looking at the actual vehicle. So
Im speculating on the possible
damages based on several alignment reports and upon the customers account of what
happened. But I think its safe to
say that the initial inspection
should center on the rear mounting point of the lower control arm.
It could be that only the control
arm is bent or its possible that the
frame mount is bent as well.
The other issue was collateral
damage. The customer complained of an intermittently hard
brake pedal and brake pull. Here
again, Im not in a position to analyze why the brakes would react
in such a fashion. A steel brake
line could, for example, have been
pinched, or the rubber brake line,
caliper guides and other related
hardware could have been damaged. All of this requires a visual
inspection by a qualified brake
technician. Other collateral damage came up after the customer
had the lower left-front control
arm replaced, but well leave that
to the last paragraph.
After the left-front lower control
arm was replaced, the driversside alignment angles were restored to -0.07 degrees camber and
+3.3 degrees caster. The camber
and caster angles arent perfect, so
they suggest that some damage
[ DiagnosticSolutions
STEERING/ALIGNMENT
sired results. So, I began recording alignment-in readings and alignment-out readings, along with mileage.
It didnt take long to compile a paper database that I
could use to fine-tune the alignment settings to my
customers driving habits.
Two years ago at a trade show, a representative
from a major alignment manufacturer demonstrated his latest machine and explained all of the
latest additions, including automatic run-out compensation and a full video for each vehicle application explaining adjustment points and tools
required. So, Ill be the first to say that this type of
machine is needed to not only enhance productivity
and create a nearly perfect wheel alignment, but
also to re-learn steering wheel centering and other
safety-related sensor inputs as well.
But, the principles I used in 1968 still apply to
modern wheel alignments:
1. Accurately determine the reason the customer
wants his/her wheels aligned.
2. Accurately analyze the significance of the
alignment data.
3. When dealing with collision damage, understand the angles of impact and the related
damages that might result.
4. Remind the customer that he might want to
notify his insurance company when collision
damage is evident.
5. Learn to fine-tune alignments to correct for
unusual vehicle loading patterns, highly cambered road surfaces and other variations in the
vehicles driving environment.
Based on my experience, following these suggestions will help provide a wheel alignment that will
meet or exceed your customers expectations. IC
[ TechFeature
Explained
30
[ TechFeature
32
A. Asbestiform
fibers, less than
0.1% by weight
Cadmium
and its compounds, less than
0.01% by weight.
Chromium (VI)-salts, less
than 0.1% by weight.
Lead and its compounds, less
than 0.1% by weight.
Mercury and its compounds,
less than 0.1% by weight.
By 2014 in California and 2015
in Washington, all brake friction
materials are restricted to no
more than 0.1% by weight of asbestiform fibers, chromium, lead
and mercury, and no more than
0.01% by weight of cadmium.
[ TechFeature
N. Contains
less than 0.5% of
copper by weight
Asbestiform
fibers, less than
0.1% by weight.
Cadmium
and its compounds, less than
0.01% by weight.
Chromium (VI)-salts, less
36
[ TechUpdate
FUEL SYSTEM
By Andrew Markel, Editor, Brake & Front End Magazine
38
[ TechUpdate
FUEL SYSTEM
Repair Procedure
1. If the fuel injector nozzles are visibly blocked, or if the injectors do not
pass the fuel injector volume test, complete the fuel injector power flush
using the following instructions:
a. Before an injector cleaning is performed, its recommended that the
following items be cleaned with Toyota Throttle Plate Cleaner or
equivalent:
Idle air control device
Throttle plate (both sides if possible)
Throttle body
(Continues on page 42)
40
[ TechUpdate
FUEL SYSTEM
42
DAN COX
owner, H&C Brakes & More
/// AutoZonePro.com. Just one more extra mile we go for guys like Dan.
K^iZbkbg`\Zklbl^Zlr_hk=Zg'Knggbg`Z[nlbg^llblgm'Pbma:nmhShg^Ikh'\hf%a^aZlma^
a^eia^g^^]lpbmaikh_^llbhgZe^lmbfZm^l%\a^\dbg`hgbgohb\^lZg]hk]^kbg`iZkml'
Hear more from Dan and get 5% off all online orders for 90 days*
Zm:nmhShg^Ikh'\hf(lahimZed'
*Excludes sales tax. See web site for complete details.
[ TechUpdate
FUEL SYSTEM
FUEL SYSTEM
TechUpdate]
What is the first thing to check if I suspect a problem with a fuel pump?
(extra $100 for multiple photos
The first thing you should do if your customers vehicle stalls or will not start is to advise them to add two
gallons of gas, if you think it might be fuel related. Sometimes, a fuel pump is diagnosed as defective for not
pumping gas when the gauge is actually inaccurate.
[ SaabFeature
CHASSIS REPAIRS
By Bob Howlett, Owner, The Swedish Solution
46
CHASSIS REPAIRS
SaabFeature]
Fig. 1
Import-Car.com
47
[ SaabFeature
CHASSIS REPAIRS
Fig. 2
Fig. 3
Fig. 5
Fig. 6
Fig. 9
Fig. 4
Fig. 7
Fig. 10
Fig. 8
48
CHASSIS REPAIRS
SaabFeature]
Fig. 12
Fig. 13
Fig. 11
Import-Car.com
49
[ SaabFeature
Fig. 14
Fig. 15
Fig. 16
Fig. 17
50
CHASSIS REPAIRS
Bookmark
favorite articles
to reference later
Read offline
(each issue is
downloadable
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Optional push
notifications
(iOS only)
ensure never
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The Library
button takes
you to an
archive of all
2013 issues of
Import Car
www.Import-Car.com
[ TechUpdate
TPMS
By Sean Phillips, Contributing Writer
d
l
r
o
W
RealTPMS Service Tips
Advice From The Field To
Reduce Comebacks And
Put Customers At Ease
f youre a shop owner or technician, you already know that TPMS has been mandatory
equipment on all cars since 2007. Youre
probably also aware that many of your customers do not know this, nor do they generally
know much about the fragile nature of the
sensors inside their tires. This disconnect can
cause customer/service adviser conflict,
especially when it comes to corrosion issues,
to which TPMS valve stems have proven
particularly and fatally vulnerable.
Corrosion weakens the TPMS sensor stem, which
makes removing stuck parts without breaking the
stem a dangerous exercise.
Corrosion problems plague nearly every part of the
valve stem:
Metal parts rust-weld to the stem and freeze.
A brass valve core mistakenly installed into
the stem, within a short period of time, will be
impossible to remove without destroying the
internal threads.
Each type of corrosion weakens the sensor
stem itself.
52
[ TechUpdate
TPMS
54
[ TechUpdate
parts wholesalers. Pearl agreed
that the availability of OE sensors
is much better than it was in the
early years of TPMS. Typically
dealers have [OE sensors] on the
shelf because its a known problem, Ryan said. I would say
that I can probably get 80%-90%
of the sensors that are out there.
OUNCE OF PREVENTION
The real key to preventing corrosion is proper maintenance of the
TPMS
56
COMMUNICATION IS KEY
As difficult as it may be to deal
with corroded valve stems, dealing with the customer can sometimes be more difficult if not
handled correctly. The importance
of communication every step of
the way was stressed by everyone
with whom we spoke.
Cudgma noted, It comes
down to the communication. If
the communication is handled
properly and the customer is
informed, there are no surprises.
But, if you break the valve stem,
and then inform the customer, it
normally doesnt go real well.
So, the best approach is to tell
[ ImportTechTips
VOLVO
CURING MANUAL
TRANSMISSION RATTLE
58
Photo 1
Photo 2
ImportTechTips]
of the DMF is within specs.
Measuring Axial Free-Play
The DMF should be removed
from the crankshaft and placed
on an even surface during the
measurement. You will need a
dial indicator.
1. Use a dial indicator and
place it as shown (see Photo 2).
The DMF should be in equal balance when the dial indicator is
put in place.
2. Apply a force of approximately 100 Nm (22.5 ft.-lbs.) on
pin (A) at the opposite side of
the dial indicator.
3. Read the distance of the axial
free-play on the dial indicator.
4. Turn the DMF 1/3 of a revolution and perform the same procedure from the beginning, applying the force on pin B.
5. Repeat the procedure for pin
C.
6. If the largest distance from
the three cases is below 2 mm
(0.078) the axial play of the
DMF is within specifications.
Replace the DMF if radial or
axial free-play measurements are
outside specifications, or if there
is physical damage to the DMF
or clutch plate surface.
Courtesy of the ALLDATA
Community Automotive Diagnostic
Team, a select group of automotive
experts dedicated to helping technicians fix hard-to-repair vehicles more
efficiently. Meet the team by visiting
http://support.alldata.com/alldatacommunity. 2014 ALLDATA LLC.
MAZDA
VARIABLE VALVE TIMING NOISE
WHEN STARTING ENGINE
Applicable Models:
2003-08 Mazda6 (2.3L)
2004-08 Mazda3 with VINs
lower than JM1BK******864673
2006-08 Mazda5 with VINs
lower than JM1CR******306808
2006-08 MX-5 with VINs lower
than JM1NC******146287
When the engine is first started,
some vehicles may exhibit a loud
ticking noise from the variable
valve timing (VVT) actuator. This is
caused by the lock pin of the VVT
actuator not fully engaging or from
a worn lock pin hole. Heat treatment has now been added around
the hole of the VVT rotor lock pin
to prevent this from happening.
Repair Procedure:
1. Verify customer concern.
2. Write down the customers
radio station presets.
3. After the engine cools down,
disconnect the negative battery
cable (to prevent DTCs from being
stored).
4. Remove the cylinder head
cover.
5. Turn the crankshaft clockwise
so that the notches on the VVT
actuator can be checked.
a. If the notches are not aligned,
go to the next step.
b. If the notches are aligned,
there is no problem with the VVT
actuator and this information is
not applicable. Refer to MS3 for
troubleshooting. (Fig. 1)
Import-Car.com
59
[ ImportTechTips
Fig. 2
Fig. 1
Fig. 3
Fig. 4
60
Essentials]
Brought to you by
<<
<<
Continental
Commercial Vehicles &
Aftermarket, a manufacturer of complete
OE Tire Pressure Monitoring Systems (TPMS),
OE-engineered TPMS
replacement parts and
the maker of the VDO
REDI-Sensor MultiApplication TPMS
Sensor, has just
released a new variant for its innovative multi-application
TPMS sensor program. The new 315 MHz sensor adds
greater coverage for Audi, Mercedes-Benz, Volkswagen,
Volvo, Subaru and other Asian models, totaling more
than 15 million additional vehicles in North America.
<<
<<
<<
61
[ Essentials
Brought to you by
<<
<<
MOOG
Steering and
Suspension
from
Federal-Mogul
Motorparts has
expanded its coverage of
late-model Asian and European
passenger vehicle applications with
several new control arms, complete strut
assemblies and other precision-engineered
parts. The latest MOOG parts for Asian applications include a rear upper control arm for the 200306 Mitsubishi Outlander, and front left and right
complete strut assemblies for 2001-07 Toyota
Sequoia SUVs.
The ODYSSEY Performance Series 34790, 78-790 and 65-760 batteries from
EnerSys are designed for consumer passenger and commercial vans, custom and
classic cars, SUVs and diesel trucks
applications that do not require as many
cold cranking amps (CCA) and reserve
capacity (RC) minutes as ODYSSEY
Extreme Series batteries. However, they
are designed with the same rugged
construction and offer equivalent deep
cycling capabilities, long service life and
high reliability.
<<
62
<<
<<
The Snap-on family of diagnostic tools gets supercharged for stronger starts and faster finishes with
Software Upgrade 14.2. The latest upgrade helps
professional
technicians
work at peak
performance
with new features such as
One-Touch
Code Scan
and the addition of Porsche coverage with the optional European
software. Upgrade 14.2 also includes new 2013 Asian
model year coverage for Honda, Hyundai, Kia and
Mitsubishi vehicles.
DIRECT CLASSIFIEDS
AD INDEX
Advertiser . . . . . . .Page Number
AAPEX . . . . . . . . . . . . . . . . .16, 17
MAHLE Clevite . . . . . . . . . . . . . .3
ADVICS . . . . . . . . . . . . . . . . . . .13
Mitchell 1 . . . . . . . . . . . . . . . . .23
Auto Value/
Bumper to Bumper . . . . .Cover 4
Stellar Automotive
(Lubegard) . . . . . . . . . . . . . . .20
Federal-Mogul
Motorparts . . . .Cover 2 Gatefold
Wagner Brakes/
Federal-Mogul . . . . . . . . .32, 33
Gates . . . . . . . . . . . . . . . . . . . .10
Intermotor/SMP . . . . . . . . . . . . .39
WORLDPAC . . . . . . . . . . . .Cover 3
64
Mercedes-Benz USA . . . . . . . . . .7
Import-Car.com
65
DIRECT CLASSIFIEDS
Advertising
Representatives
The Tech Group
Bobbie Adams
badams@babcox.com
330-670-1234, ext. 238
Sean Donohue
sdonohue@babcox.com
330-670-1234, ext. 206
Jamie Lewis
jlewis@babcox.com
330-670-1234, ext. 266
Dean Martin
dmartin@babcox.com
330-670-1234, ext. 225
Glenn Warner
gwarner@babcox.com
330-670-1234, ext. 212
John Zick
jzick@babcox.com
805-845-1400
Classified Sales
Tom Staab
tstaab@babcox.com
330-670-1234, ext. 224
66
DIRECT CLASSIFIEDS
Import-Car.com
67
[ ImportInsights
Volkswagen
Spotlight on Seventh-Generation Golf GTI
Engine
The Golf GTI features
an EA888 2.0-liter turbocharged and directinjection TSI engine
that creates 210 hp and
258 lb.-ft. of torque,
increases of 10 hp and 51 lb.-ft over the previous-generation GTI model. The new engine is designed to be
both lighter than the old unit and reduce friction.
Augmenting the EA888s 16-valve, DOHC layout is the
latest variable cam phasing system, which controls both
intake and exhaust valves, as well as a variable lift system
for the valves themselves. The single-scroll turbocharger
feeds intercooled air through the aluminum-alloy
crossflow cylinder head. Fuel is delivered by the latest
high-pressure direct-fuel-injection system at 2,900
pounds per square inch, compared to 2,176 psi on the
previous EA888 engine.
The engine is also extremely compact, illustrated by
the way in which the exhaust headers have been integrated directly into the cylinder head. This improves the
systems coolant operation.
68
The Seventh-generation
Golf GTI is bigger,
lighter, faster and more
fuel-efficient than the
previous generation,
with increases in horsepower and torque as
well as an improvement
in fuel economy.
Suspension
& Chassis
As the first U.S.market vehicle built
on Volkswagens
MQB modular platform, the new Golf GTI
features an all-new body-in-white. The unitary
construction chassis has two solid-mounted
subframes with bolt-on front fenders.
The new Golf GTI features a strut-type front
suspension with lower control arms and a
multilink rear suspension, both of which are
controlled by coil springs with telescopic
dampers. The Golf GTI has a lowered sport
suspension, which is 0.6 inches lower than the
Golf TSI and TDI Clean Diesel models. The
front suspension includes a 24-mm anti-roll
bar, while the rear has a 20-mm version.
The all-new Golf GTI comes equipped with
large 12.4-inch vented front discs and 10.7inch solid rear discs with standard three-channel ABS with electronic brake pressure
distribution. Opting for the Performance
Package increases brake disc size even further,
to 13.4-inch front and 12.2-inch rear vented
discs, with single-piston calipers all around.
Brake Job
Guide
GMC Acadia
Honda Accord
Ford Mustang
Toyota Tundra
Toyota Prius
Ford Explorer
Brake Job
Your Guide to Performing
Application Specific Brake Jobs
Guide
With five different brake configurations, a little due diligence can save
time and prevent comebacks.
www.PerfectStop.com
Rear Pads
Inspect the dust boots for
damage and replace the caliper
if necessary. Inspect the guide
pins and replace and lubricate if
Parking Brake
The parking brake is located
in the hat section of the rear
rotor. It is applied mechanically
by a cable actuated cam and
lever located in the bottom of
the backing plate. The shoes
are attached to the backing
GMC
ple and requires pressing the
brake and gas in the right
sequence.
Bleeding
Like most modern brake systems with ABS, the system has
Pads:
Front
Perfect Stop
PS1169AC
Rear
Perfect Stop
PS883C
Rotors:
Perfect Stop
Premium Black Hat
PS126467 (Front)
PS126503 (Rear)
Hardware:
Included with Perfect
Stop pads.
Front Brakes
1. Remove the brake hose
mounting bolt.
2. Remove the lower flange
bolt while holding the flats behind the flange with a wrench.
Do not spin the caliper pin in
the bore. Damage can occur to
the bore and pin boot.
3. You can rotate the caliper
upward and secure it if you are
just replacing the pads. If not,
remove the upper flange bolts.
Honda
10. Install the brake pads and
pad shims on the new pads.
Install the brake pads with the
wear indicator on the inside,
top of the pad.
11. Gently push in the piston
so the caliper will fit over the
new rotor and/or pads.
12. Install the flange bolt and
tighten it to 26 ft.-lbs. for the
smaller system and 37 ft.-lbs.
for the larger system.
13. Install hose mounting
bolt.
Parking Brake
1. Pull the parking brake lever
with 44 lbs of force to fully
apply the parking brake (use a
fish scale). The parking brake
lever should be locked within
three to five clicks.
2. Adjust the parking brake.
For drum brake vehicles,
loosen the parking brake adjusting nut, start the engine
and press the brake pedal several times to set the self-adjusting brake before adjusting
the parking brake.
3. Remove the center console.
4. Pull the parking brake lever
up one click.
5. Tighten the adjusting nut
until the parking brakes drag
slightly when the rear wheels
are turned.
6. Release the parking brake
lever fully and check that the
parking brakes do not drag
when the rear wheels are
turned. Readjust if necessary.
7. Pull the parking brake all
the way up and make sure the
parking brakes are fully applied.
8. Reinstall the center
console.
Pads:
Front
Perfect Stop
PS914C (2.4L, OE Ceramic)
PS787C (3.0L, Japan Built)
PS959C (3.0L, U.S. Built)
Rear
Perfect Stop
PS537C (Disc Pads)
PSS627 (Shoes)
Rotors:
Perfect Stop
Premium Black Hat
PS125669 (Front, 282 mm)
PS125674 (Front; 300 mm)
PS126082 (Rear)
Hardware:
Included with Perfect
Stop pad set.
Brake Inspection
Ford says the minimum
thickness specification
for the pads is 3.0
mm (0.118 in.). So if
theres less than
1/8th of an inch of
friction material left
on the pads, its
time to replace
them.
The minimum rotor
thickness specification for the front rotors
on both the V6 and V8
Mustangs is 28.4 mm (1.11
in.), and 17.4 mm (0.68 in.) for
the rear rotors. The minimum
thickness specifications for the
larger Shelby GT 500 front rotors is 30.0 mm (1.181 in.).
The minimum machine to
spec is about 0.6 mm more than
the minimum thickness specification: 29 mm for the V6 and V8
front rotors, and 18 mm for the
rear rotors (30.6 mm for the
Shelby front rotors). This will
allow for wear until the next time
the brake pads are replaced.
The front rotors on a V6 Mustang can be upgraded to the
larger stock V8 rotors, but they
require 17-in. or larger wheels
for clearance. If a set of 13- or
14-in. aftermarket performance
rotors are being mounted in
Ford
caliper aside. Support the
caliper with a wire.
2. Remove the old pads from
the rear caliper and discard the
old spring clips.
3. Important: Use special tool
206-026 (T87P-2558-A) or equivalent to screw in the rear caliper
pistons for pad clearance. Do
not attempt to force the rear
pistons in with a C-clamp as
this can damage the piston
mechanism.
4. Inspect the caliper. If leaks
or damaged boots are found,
rebuild or replace the caliper.
5. Inspect the brake caliper anchor plate assembly. Check the
guide pins and boots for binding
and damage. Replace worn or
damaged pins. Lubricate the
pins with brake grease. Install a
new brake caliper anchor plate if
it is worn or damaged.
6. Measure rotor thickness.
(24 ft.-lbs.).
10. Check the adjustment of
the parking brake and adjust
as needed. Adjustments are
made by removing a small access cover inside the center
console bin. Position the
brake handle at the fourth
notch, loosen the adjuster
nut/lock nut and then tighten
the main nut as needed to
tighten the brake cables.
11. Flush and bleed the brakes
using any method you choose.
The standard bleeding sequence
is right-rear, left-rear, right-front
and left-rear. Use DOT 3 brake
fluid.
Pads:
Front
Perfect Stop
PS1081C (Base & GT)
PS1050AM (GT500)
Rear
Perfect Stop
PS1082C (Base & GT)
PS1082M (GT500)
Rotors:
Perfect Stop
Premium Black Hat
PS126198 (Front Base 11.54)
PS126211 (Front GT 12.43)
PS900918 (Front GT500 13.98)
PS126273 (Rear)
Hardware:
Included with select
Perfect Stop pad sets.
COMPONENT
ILLUSTRATION
Front Brakes
Toyota
to the piston boots.
The OE friction formulation on
the Tundra is ceramic. A
replacement brake pad should
be of a similar formulation.
Do not lubricate the back of
the pad with any lubricant. The
lubricant will only transfer onto
the piston boots and cause
them to attract debris. This can
lead to an early failure.
Pulsation is an issue with
some 2007-2009 Tundra models. Most of the issues are related to excessive runout or
uneven deposits of friction material on the rotor. The runout
specification on the Tundra is
.05 mm (.002-in.) The hub
flange should have almost zero
Parking Brake
runout.
Rear Brakes
The 2007 Tundra is equipped
with disc rear brakes with the
parking brake in the hub. The
caliper is a floating design
with a single piston. The OE
friction formulation is ceramic.
Pads:
Front
Perfect Stop
PS1303C
Rear
Perfect Stop
PS1304C
Rotors:
Perfect Stop
Premium Black Hat
PS126490 (Front)
PS126554 (Rear)
Brake Pads
Look at the brake pads for
any sign of abuse. Look for
signs of rust jacking between
the backing plate and friction
material. This causes edge lift
and material separation. The
customer may also notice noise
and vibration.
The minimum thickness for
the pads is 3 mm, which is a lot
of material to the naked eye.
Rotors
Technicians are often confused by Fords rotor specs. In
the past, Ford printed or
stamped the minimum and discard thickness of the rotors.
Now they call it thickness to
machine. Confused? The minimum thickness is the thickness
Ford
Front/rear hose banjo/flow
bolt: 26 ft.-lbs.
Hard brake line fittings: 13 ft.-lbs.
Front caliper bolt: 24 ft.-lbs.
Rear caliper bolt: 24 ft.-lbs.
Front caliper bracket anchor
bolts: 100 ft.-lbs.
Lug nuts: 100 ft.-lbs.
Bleeding
Repair Procedure
Some Explorers have adjustable gas and brakes pedals.
The adjustment switch is located
on the dash. On vehicles with
memory seats, the position of
the pedals is dependent on
which key us used to unlock and
start the vehicle. It has been reported that if the pedal assembly
is inoperative or stuck between
positions, it may cause the driver
to notice a change in brake
pedal feel and performance. During the inspection process, verify
that the adjustable pedals are
still operational. If the pedals are
stuck, contact the customer to
get more information.
For the caliper anchor pins,
use a silicone-based brake
grease. Make sure it is compatible with all rubber compounds
including nitrile, Teflon, nylon
and other synthetic rubbers.
For the shims, abutment clips
and slides, use a syntheticbased, boundary-type lubricant
that has a high solids content
and typically contains a variety
of friction-reducing ingredients,
such as molybdenum disulfide
(moly or MOS2) and graphite.
Ford recommends applying a
thin coat of anti-seize lubricant
to the hub flange only. Do not
allow the lubricant to make con-
Emergency Brake
Adjustments
1. Remove the rear rotor.
2. Inspect the parking/emergency brake mechanism. Lubricate the parking brake shoes at
the point where they contact
the brake disc shield using silicone grease.
3. Use a brake adjusting
gauge/calipers to measure the
inside diameter of the drum position of the rear brake disc. Adjust the parking brake shoe
clearance of 107 mm (0.142 in.)
to less than the inside diameter
of the drum portion of the rear
brake disc.
4. Make sure that the parking
brake shoes are correctly centered and measure across the
center point.
5. Rotate the parking brake
shoe adjuster wheel to achieve
the correct parking brake shoeto-brake disc.
Torque Specs
Bleeder screws: 16 ft.-lbs.
Pads:
Front
Perfect Stop
PS1158C
Rear
Perfect Stop
PS1109C
PSS791 (Parking Brake Shoe)
Rotors:
Perfect Stop
Premium Black Hat
PS126346 (Front)
PS125759 (Rear)
Hardware:
Included with select
Perfect Stop pad
sets.
Pads
Always use a high-quality pad
for the Prius and other hybrid
applications to avoid problems.
It is not a question of better
performance, it is a question of
quality and engineering. It is
impossible to perform a conventional break-in/bedding procedure on the test drive.
Perfect Stop Ceramic Pads are
OE scorched for excellent performance right out of the box.
Rotors
There is nothing special about
servicing the rotors on this vehicle, but if you are planning to
use an on-the-car brake lathe,
make sure the system is off for
two minutes. Most on-the-car
brake lathes operate below the
speed threshold of the generators ability to generate voltage.
Rotors that have excessive
runout or thickness variation
can cause hydraulic pulsations
in the brake circuit. These irregularities can cause the pressure
sensor to trigger trouble codes
C1341 thru C1344 that indicate
a hydraulic circuit malfunction.
Toyota
from the pin slides.
3. Remove the pads and inspect the friction material for
glazing, corrosion, edge lift or
other mechanical damage.
Using a ruler, measure the pad
lining thickness from the base
of the backing plate to the friction surface. Also, make sure
the inside and outside pads are
evenly worn.
Standard thickness: 11.0 mm
(0.433 in.).
Minimum thickness: 1.0 mm
(0.039 in.).
4. Remove the two anti-squeal
shims from the pads.
5. Remove the caliper brackets. Inspect the surfaces for corrosion and mechanical damage.
6. Remove the slide pins, dust
boots and pad abutment clips
from the caliper bracket. Clean
the bracket with brake cleaner.
7. Check the looseness of the
front wheel bearing and runout
in the axle hub before removing
the rotor. Hold the front disc
with the lug nuts.
8. Using a micrometer, measure the rotors thickness in at
least six areas.
9. Before removing the rotor,
mark the high and low points of
runout. Also, mark the rotors
position on the hub.
10. Machine the rotor with either a bench or on-the-car
brake lathe.
11. Install the caliper support
Pads:
Front
Perfect Stop
PS990C
Rear (Shoes)
Perfect Stop
PSS917
Rotors:
Perfect Stop
Premium Black Hat
PS126226 (Front)
Drums:
Parts Master
920148 (Rear)