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Home >> Volkswagen >> 2012 >> Routan S >> Repair and Diagnosis >> External Pages >> Different car >> Section 320 (Brake System - General Information) >> General Procedures >> Brake Disc Machining >> Brake Disc Machining
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Brake Disc Machining

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not use a bench lathe to machine the brake discs.
NOTE: Read the entire operating manual and view the video shipped with the lathe before installing, operating, or repairing the lathe.
NOTE: Do not machine new brake discs.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe makes sure that these dimensions are within specifications.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
    CAUTION: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components.

    2. Hybrid vehicles 

    NOTE: The following steps must be followed to prevent the accumulator from charging and pressurizing the brake system.
  2. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the battery junction box (BJB) fuses 24 (50 A) and 31 (50 A).

    4. All vehicles 

    NOTE: It is not necessary to disconnect the brake line from the brake caliper.
  4. Position the brake caliper and brake caliper anchor bracket (if equipped) aside. For additional information, refer to FRONT DISC BRAKE for front disc brakes or REAR DISC BRAKE for rear disc brakes.
  5. Machine the brake disc using the on-car brake lathe.
    1. Install the hub adapter and silencer belt, if necessary.
    2. Install the cutting lathe.
    3. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated reading (TIR) target is 0.000 mm (0.000 in), and the maximum is 0.08 mm (0.003 in).
    4. Center the cutting head, adjust the cutting bits, and install the chip deflector.
      5. NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 in). Lighter cuts cause the bit to heat up and wear faster. Heavier cuts cause poor brake disc surface finish.
    5. Machine the brake disc.
    6. Remove the lathe and, if installed, the silencer belt.
    7. Remove the hub adapter.
  6. Remove the metal shavings.
    7. NOTE: It is not necessary to install new brake pads if the friction material properties are within specification. Refer to SPECIFICATIONS .
  7. Install the brake caliper and brake caliper anchor bracket. For additional information, refer to FRONT DISC BRAKE for front disc brakes or REAR DISC BRAKE for rear disc brakes.
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