Canada - Brakes - Front Brake Rotors Rusting

Bulletin
TSB2099

Issue Date
September 22, 2004


Market
Canada


Title
BRAKE ROTOR RUST

Component
BRAKES

Models
All Echo

Some customers may experience brake vibration on all model year Echo vehicles due to front brake rotor rust. This condition may occur after the customer has driven the vehicle for an extended period of time in an environment where road salt is used for snow or ice removal. To correct this concern, it is recommended to replace the rotors and pads as a set.

APPLICABLE VEHICLES:
- All model year Echo vehicles.






WARRANTY INFORMATION:

REPAIR PROCEDURE:

1. Remove Wheel.
A. Remove the wheel and temporarily fasten the disc with hub nuts.







2. Remove Brake Caliper.
A. Hold the sliding pin and loosen the 2 installation bolts, and remove the 2 installation bolts.
B. Remove the caliper from the torque plate.
C. Support the brake caliper securely.

3. Remove Brake Pads with Anti-squeal Shims.







4. Replace Disc Rotor.
A. Remove the 2 mounting bolts and torque plate from the knuckle.
B. Remove the disc rotor.
C. Install a new disc rotor.
D. CHECK RUNOUT by referring to the ETAS for Repair Manual: Brake; Front Brake Caliper
E. Install the torque plate to the knuckle with the 2 mounting bolts.

Torque: 88 N-m (900 kgf-cm, 65 ft-lbf)

5. Install New Pads.

NOTE:
When replacing worn pads, the anti--squeal shims and pad wear indicator plates must be replaced together with the pads.







A. Apply disc brake grease to both sides of the anti--squeal shims.
B. Install the 2 anti--squeal shims on the outer pad.
C. Install the 2 anti--squeal shims on the inner pad.
D. Install the inner pad with the pad wear indicator plate facing upward.
E. Install the outer pad.

NOTE:
There should be no oil or grease adhering to the friction surfaces of the pads or the disc.







6. Install Caliper.
A. Draw out a small amount of brake fluid from the reservoir.
B. Press in the piston with a hammer handle or similar implement.

HINT:
If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape.

C. Install the caliper.
D. Hold the sliding pin and install the installation bolt.
Torque: 34 N-m (350 kgf-cm, 25 ft-lbf)

7. Install Front Wheel.
Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbf)