Chevrolet Captiva Manuals

Chevrolet Captiva Service & Repair Manual: Brake Rotor, Reface

On Vehicle

An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if lathe is not self adjusting, lathe oscillation must be adjusted using a dial indicator. Total indicated runout target is .000 inch. Maximum indicated runout should be no more than .002 inch. If runout adjustment (automatic or manual) is carried out correctly prior to machining, final brake disc runout will be within specification and a runout measurement is not required after machining.
Lateral runout and disc thickness variation measurements are not required because correct adjustment of on-vehicle brake lathe will ensure that these dimensions are within specification.
Do not allow caliper to hang from brake hose or damage to hose may occur.
1. Remove wheel and tire as outlined in "Wheel, Replace."
2. Remove bolts and position brake caliper or brake caliper and anchor plate assembly aside, as required. Support brake caliper using mechanic's wire.
3. Install hub adapter.
4. Install cutting lathe.
5. If lathe is not self adjusting, adjust lathe oscillation using a dial indicator. Total indicated runout target is .000 inch. Maximum indicated runout should be no more than .002 inch.
6. Center cutting head, adjust cutting bits and install chip deflector/silencer.
7. Machine brake disc. Depth of cut should be between .004 and .015 inch. Lighter cuts will cause bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish.
8. Remove lathe and silencer.
9. Remove wheel nuts and hub adapter.
10. Remove metal shavings.
11. Measure brake disc thickness. If measurement is below minimum specification, install a new brake disc.
12. It is not required to install new brake pads if friction material is within specifications.
13. Install brake caliper or brake caliper and anchor plate assembly.
14. Install wheel and tire as outlined in "Wheel, Replace."

Off Vehicle

To achieve adequate results using brake lathes follow manufactures instructions and recommendations.
Accurate control of rotor tolerances is required for proper performance of disc brakes, machining of rotor should be done only with precision equipment.
All brake rotors have a maximum diameter cast into them. This diameter is maximum wear diameter and not a refinish diameter. Do not refinish a brake rotor that will not meet specifications. Any rotor which does not meet specifications should be replaced.
When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.
Optimum speed for refinishing braking surfaces is a spindle speed of 200 RPM. Crossfeed for rough cutting should range from .006-.010 inch per revolution. Finish cuts should be made at crossfeeds no greater than .002 inch per revolution. Lathe finish cuts should be made non-directional by dressing rotor surface with a suitable sanding disc power tool.
1. Do not refinish disc brake rotors in an attempt to correct following conditions:
  a. Brake system noise, squeal, growl or groan.
  b. Uneven and/or premature disc brake pad wear.
  c. Superficial or cosmetic corrosion/rust of disc brake rotor friction surface.
  d. Scoring of disc brake rotor friction surface less than maximum allowable specification.
2. Disc brake rotors should only be refinished if they have adequate thickness to be refinished. Discard if one or more of following conditions exist:
  a. Thickness variation in excess of maximum allowable specification.
  b. Excessive corrosion/rust and/or pitting.
  c. Cracks and/or heat spots.
  d. Excessive blueing discoloration.
  e. Scoring of disc brake rotor surface in excess of maximum allowable specification.
3. Mount brake rotor to brake lathe according to lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris.
4. Ensure that any vibration dampening attachments are securely in place.
5. With brake lathe running, slowly bring in cutting tools until they just contact brake rotor friction surfaces.
6. Observe witness mark on brake rotor. If witness mark extends approximately 3/4 or more around brake rotor friction surface on each side, brake rotor is properly mounted to lathe.
7. If witness mark does not extend 3/4 or more around brake rotor, mount rotor to lathe.
8. Following brake lathe manufacturer's instructions, refinish brake rotor.
9. After each successive cut, inspect brake rotor thickness.
10. If at any time brake rotor exceeds minimum allowable thickness after refinish specification, brake rotor must be replaced.
11. After refinishing brake rotor, use following procedure in order to obtain desired non-directional finish:
  a. Follow brake lathe manufacturer's recommended speed setting for applying a non-directional finish.
  b. Apply non-directional finish using moderate pressure.
  c. If lathe is equipped with a non-directional finishing tool, apply finish with 120-grit aluminum oxide sandpaper.
  d. If lathe is not equipped with a non-directional finishing tool, apply finish with a sanding block and 150-grit aluminum oxide sandpaper.
  e. After applying a non-directional finish, clean each friction surface of brake rotor with a solution of mild dish washing detergent and water, or an approved brake cleaner and a clean shop towel to remove metal particles remaining from machining. Repeat cleaning process if required to remove all metal particles.
12. Remove brake rotor from brake lathe.
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