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Mazda RX7. Manual - part 85

VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95

Article Text

1983 Mazda RX7

For www.iluvmyrx7.com

Monday, September 03, 2001 03:36PM

ARTICLE BEGINNING

TECHNICAL SERVICE BULLETIN

BRAKE JUDDER REPAIR

Model(s): All Mazda Models Through 1995
Category: P
Bulletin No.: 001/95
Date: April, 27 1995

NOTE: This bulletin replaces Service Bulletin Cat. P, 006/94 dated
Sept. 1994.

DESCRIPTION

Customers who complain of vibration or pulsation in the steering
wheel, brake pedal, floor or seat while applying the brakes may be
experiencing symptoms of brake judder. Judder is caused by:

  * Disk Thickness Variation (DTV)
  * rotor run-out and/or
  * rotor surface rust (which leads to DTV)

This bulletin describes the causes and corrections for each condition.

CAUSES OF JUDDER

1. Disc Thickness Variation (DTV) - DTV creates a vibration/pulsation
during application of the brakes. DTV will increase with mileage
accumulation if the run-out of the disc is excessive.

2. Disc Rotor Run-Out - Run-out, or rotor "wobble", leads to DTV. It
is corrected by precision machining to bring the run-out within
specification.

3. Rotor Surface Rust - Under certain conditions (storage or use in
extreme environments), the surface of the brake rotors may become
rusted in the pad non-contact area. If this I corrosion penetrates
the rotor surface deeply enough, it will not wear or rub off
during normal use. This will cause DTV.

CORRECTION

In order to effectively correct brake judder, rotor surfaces must be
precisely machined. Mazda has evaluated both on and off-car brake
lathes and has determined that on-car lathes are more precise and
greatly reduces comeback repairs.

The steps necessary for correction of brake judder are as follows:

VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95

Article Text (p. 2)

1983 Mazda RX7

For www.iluvmyrx7.com

Monday, September 03, 2001 03:36PM

1. If the vehicle is in dealer inventory and the condition is rotor
rust:

a. Clean the rotor surface by driving the vehicle several miles
while frequently applying the brakes.
b. If vibration/pulsation is still felt, processed to step "c".
c. Machine the rotor surface enough to remove all rust or surface
staining (generally 0.1 mm per side).

NOTE: If machining is performed, the Service Manager's signature must
appear on the repair order.

2. If the vehicle has been in service:

a. Verify customer's complaint with a test drive.
b. If brake judder is felt, proceed to step c. If brake judder is
not felt, refer to the work shop manual or the NVH manual for
additional troubleshooting information.
c. Mark the front wheel(s) and the lug nut stud with chalk. This
will determine the original position of the wheel to the
rotor. Remove the front wheel(s).

NOTE: A high majority of brake judder is due to DTV of the front
rotors. Customer complaints of brake judder are most often
corrected by machining the front rotors only.

d. Measure the remaining front rotor thickness and run-out.
Determine if sufficient rotor material remains to allow
machining. Limit: Stated minimum thickness for the model plus
0.8 mm.
e. If machining can be achieved, an on-car brake lathe is
recommended and will be required for all warranty repairs
after January 1, 1995 to ensure a precise rotor surface.

NOTE: After machining rotor(s) with an on-car brake lathe, you must
remove all metal cuttings (particles) from the ABS "toothed
ring" (the reluctor) and the ABS sensor. Failure to remove
these particles will prevent proper function of the ABS system.

f. If machining can not be achieved due to rotor thickness
limitations, the dealer should replace the rotor. To ensure a
successful repair, run-out and/or DTV must be removed by
on-car machining, even on new rotor(s).
g. Install the wheel in the same location relative to the hub as
it was originally positioned.
h. Torque wheel lug nuts to the specifications in the service
manual.
i. Test drive the vehicle to confirm repair.
j. If the brake judder is still felt, correct the rear rotor(s)
using steps "c" through "i".

VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95

Article Text (p. 3)

1983 Mazda RX7

For www.iluvmyrx7.com

Monday, September 03, 2001 03:36PM

SERVICE TOOLS

The Accu-Tum (model 8750) On-Car Brake Lathe is recommended by Mazda.
The brake lathe will be available soon from MMA's National Accounts
Program at a substantial savings. When the national account is
established, a Special Tools Service Bulletin will be released which
will combine further details. However, if you wish to receive a
brochure on this brake lathe, please call Accu-Turn at (800) 551-2228.

WARRANTY INFORMATION

(Applies To Vehicles Covered Under Normal Warranty.)

Warranty Type: A
Symptom Code: 83
Damage Code: 9B
Part Number Main Cause: **** 33 25
**** 26 25 (Rear of Vehicle - Rear Wheel
Drive Only)

Operation Number: P0113AMX/0.7 hrs. (Front/One Side)
P0113BMX/1.2 hrs. (Front/Both Sides)
P0214AMX/0.7 hrs. (Rear/One Side)
P0214BMX/1.2 hrs. (Rear/Both Sides)

NOTE: 1. Unnecessary replacement of rotors will result in warranty
claim denial.
2. Brake pad replacement costs will not be warrantable for
brake judder repair.
3. If an on-car lathe is used, apply the labor time from the
table above.

NOTE: Warranty policy does not permit using an off-car brake lathe
after January 1, 1995. The next issue of the SRT microfiche
will
be revised to show new labor times.

BRAKE DRUMS LABOR OPERATION/TIME CODES - 1993-1995 MODELS

626/MX-6
Rear Brakes/Brake Drums(s), R&R (one side)
Labor Operation: P0201ARX/0.3 hrs.
Rear Brakes/Brake Drums(s), R&R (both sides)
Labor Operation: P0201BRX/0.4 hrs.
Brake Drum(s), Machine (one side)
Labor Operation: P0201AMX/0.5 hrs.
Brake Drum(s), Machine (both sides)
Labor Operation: P0201AMX/0.7 hrs.
Brake Shoe(s), R&R (one side)
Labor Operation: P0204ARX/0.4 hrs.
Brake Shoe(s), R&R (both sides)

VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95

Article Text (p. 4)

1983 Mazda RX7

For www.iluvmyrx7.com

Monday, September 03, 2001 03:37PM

Labor Operation: P0204BRX/0.6 hrs.

MPV (1993 Models only)
Rear Brakes/Brake Drums(s), R&R (one side)
Labor Operation: P0201ARX/0.3 hrs.
Rear Brakes/Brake Drums(s), R&R (both sides)
Labor Operation: P0201BRX/0.6 hrs.
Brake Drum(s), Machine (one side)
Labor Operation: P0201AMX/0.3 hrs.
Brake Drum(s), Machine (both sides)
Labor Operation: P0201AMX/0.6 hrs.
Brake Shoe(s), R&R (one side)
Labor Operation: P0204ARX/0.5 hrs.
Brake Shoe(s), R&R (both sides)
Labor Operation: P0204BRX/0.8 hrs.

323/PROTEGE
Rear Brakes/Brake Drums(s), R&R (one side)
Labor Operation: P0201ARX/0.3 hrs.
Rear Brakes/Brake Drums(s), R&R (both sides)
Labor Operation: P0201BRX/0.6 hrs. (1993-94)
Labor Operation: P0201BRX/0.3 hrs. (1995)
Brake Drum(s), Machine (one side)
Labor Operation: P0201AMX/0.3 hrs.
Brake Drum(s), Machine (both sides)
Labor Operation: P0201AMX/0.6 hrs.
Brake Shoe(s), R&R (one side)
Labor Operation: P0204ARX/0.5 hrs. (1993-94)
Labor Operation: P0204ARX/0.3 hrs. (1995)
Brake Shoe(s), R&R (both sides)
Labor Operation: P0204BRX/0.8 hrs. (1993-94)
Labor Operation: P0204BRX/0.5 hrs. (1995)

MX-3
Rear Brakes/Brake Drums(s), R&R (one side)
Labor Operation: P0201ARX/0.3 hrs.
Rear Brakes/Brake Drums(s), R&R (both sides)
Labor Operation: P0201BRX/0.4 hrs.
Brake Drum(s), Machine (one side)
Labor Operation: P0201AMX/0.3 hrs.
Brake Drum(s), Machine (both sides)
Labor Operation: P0201AMX/0.6 hrs.
Brake Shoe(s), R&R (one side)
Labor Operation: P0204ARX/0.4 hrs.
Brake Shoe(s), R&R (both sides)
Labor Operation: P0204BRX/0.6 hrs.

93 B-Series and earlier
Rear Brakes/Brake Drums(s), R&R (one side)
Labor Operation: P0201ARX/0.3 hrs.
Rear Brakes/Brake Drums(s), R&R (both sides)
Labor Operation: P0201BRX/0.6 hrs.

Content .. 83 84 85 86 ..