Uniform Inspection and Communication Standards

A - Part no longer performs intended purpose

B - Part does not meet a design specification (regardless of performance)

C - Part is missing

1 - Part is close to the end of its useful life (just above discard specifications, or weak; failure likely to occur soon, etc.)

2 - To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.)

3 - To comply with maintenance recommended by the vehicle’s Original Equipment Manufacturer (OEM)

4 - Technician’s recommendation based on substantial and informed experience

CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid in a system equipped with ABS. DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light amber in color. DOT 5 brake fluid is violet in color. Correct fluid type is normally stamped on the master cylinder cover.

At or beyond OEM service interval

3

Suggest fluid replacement

Brake fluid type incorrect

B

Require flushing and refilling

NOTE: For example, DOT fluid lower than specified for the vehicle or silicone brake fluid (DOT 5) in an ABS system

Contaminated, for example, fluid other than brake fluid present

A

Require service

NOTE: If a fluid other than brake fluid is present in the brake system which DOES affect the rubber parts, the required service is to:
1) remove all components having rubber parts from the system;
2) flush lines;
3) repair or replace all components having rubber parts; and
4) fill with correct brake fluid.

Contaminated, for example, fluid other than brake fluid present

B

Require service

NOTE: If a fluid other than brake fluid is present in the brake system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct brake fluid.

Corrosion inhibitors depleted

B

Require fluid replacement

NOTE: A copper content of 200 ppm or greater indicates a depletion of corrosion inhibitors in the brake fluid

Hydraulic component overhaul or replacement

3

Suggest flushing and refilling

Rubber master cylinder cover gasket distorted and gummy

A

Require replacement of gasket

NOTE: This condition may indicate contaminated brake fluid. Further inspection required.

Determine the need to recondition based upon individual rotor conditions that follow. Friction material replacement does not require rotor reconditioning unless other justifications exist. Do not recondition new rotors unless they are being pressed or bolted onto an existing hub. It is not necessary to replace rotors in axle sets. However, when replacing or reconditioning a rotor due to the conditions that follow, you may suggest reconditioning of the other rotor on the same axle to eliminate uneven braking behavior. Determine the need to replace based upon the individual rotor conditions that follow. Reconditioning is defined as machining and block sanding, or block sanding only. Block sanding is defined as using 120-1 50 grit sandpaper with moderate to heavy force for 60 seconds per side. Always wash rotors after servicing or before installing.

Corrosion affecting structural integrity

A

Require replacement

NOTE: Examples of severe corrosion are: composite plate separated from friction surfaces and cooling fins cracked or missing.

Cracked

B

Require replacement

Hard spots

2

Suggest reconditioning or replacement of rotor according to OEM specifications

Lateral runout (wobble) exceeds OEM specifications

B

Require re-indexing, reconditioning, or replacement according to specifications

Measured thickness is less than OEM discard specifications

B

Require replacement

Rotor thickness is less than OEM 'machine to' specifications but thicker than 'discard at' specifications, and rotor does not require reconditioning

1

Suggest replacement

NOTE: Only applies to vehicles for which OEM "machine to" specifications exist. If OEM does not supply "machine to" specifications, the rotor may be worn to discard specifications.

Rotor thickness will be less than OEM 'machine to' specifications after required reconditioning

B

Require replacement

NOTE: If OEM does not supply "machine to" specifications, you may machine to discard specifications

Surface is rust-pitted

B

Require reconditioning or replacement of rotor according to OEM specifications

Surface is scored

B

Require reconditioning or replacement of rotor according to OEM specifications

NOTE: Scoring is defined as grooves or ridges in the friction contact surface. Some vehicle manufacturers require machining when scoring exceeds their allowable specifications.

Thickness variation (parallelism) exceeds OEM specifications

B

Require reconditioning or replacement of rotor according to OEM specifications