brake & front end, dec. 2012

®

A MAGAZINE

�Viewpoint: Copper in Brake Pads �Gonzo: Second-Hand Info �Oxygen Sensor FAQ

December 2012BrakeandFrontEnd.com

Circle #2 for Reader Service

28

1812

A Publication

Sales Representatives:

Bobbie [email protected], ext. 238

Doug [email protected] 330-670-1234, ext. 255

Sean [email protected], ext. 206

Dean Martin [email protected] 330-670-1234, ext. 225

Glenn [email protected] 330-670-1234, ext. 212

John Zick [email protected] 949-756-8835

List Sales Manager

Don [email protected], ext. 286

Classified Sales

Tom [email protected], ext. 224

ADVERTISING REPRESENTATIVES

HOME OFFICE

3550 Embassy Parkway Akron, Ohio 44333-8318330-670-1234FAX 330-670-0874www.babcox.com

PRESIDENT

Bill [email protected], ext. 217

VICE PRESIDENT

Jeff [email protected], ext. 282

Brake and Front End is a member of and supports the following organizations:

BRAKE & FRONT END (ISSN 0193-726X)(December 2012, Volume 84, Number 12): Published monthly by Babcox Media, 3550 Embassy Parkway, Akron, OH 44333 U.S.A. Phone (330) 670-1234, FAX (330) 670-0874.Periodical postage paid at Akron, OH 44333 and additional mailing offices. POSTMASTER: Send address changes to BRAKE & FRONT END, P.O. Box 13260, Akron, OH 44334-3913.BRAKE & FRONT END is a trademark of Babcox Publications, Inc. registered with the U.S. Patent and Trademark office. All rights reserved.A limited number of complimentary subscriptions are available to individuals who meet the qualification requirements. Call (330) 670-1234, Ext. 260, to speak to a subscription servicesrepresentative or FAX us at (330) 670-5335. Paid Subscriptions are available for non-qualified subscribers at the following rates: U.S.: $69 for one year. Canada: $89 for one year.Canadian rates include GST. Ohio residents add current county sales tax. Other foreign rates/via air mail: $129 for one year. Payable in advance in U.S. funds. Mailpayment to BRAKE & FRONT END, P.O. Box 75692, Cleveland, OH 44101-4755. VISA, MasterCard or American Express accepted.

04 Viewpoint

06 Gonzo’s ToolBox

08 Aftermarket News

12 WIX Tech of the Year

16 Products

18 Brake Job

24 Alignment Specs

26 Oxygen Sensor

28 TPMS & TSBs

32 Tech Tips

35 Classifieds

37 Ad Index

40 Brake Lights

EditorAndrew Markel, ext. 296email: [email protected]

Managing Editor Tim Fritz, ext. 218email: [email protected]

Technical Editor Larry Carley

Contributing Writers Gary Goms, Scott “Gonzo” Weaver, Larry Bailly, Bob Dowie and Randy Rundle

Graphic Designer Dan Brennan, ext. 283email: [email protected]

PublisherJim Merle, ext. 280 email: [email protected]

Advertising Director Cindy Ott, ext. 209email: [email protected]

Circulation Manager Pat Robinson, ext. 276email: [email protected]

Circulation AssistantKim Hedgepeth, ext. 260email: [email protected]

978th Issue, Volume 84, No. 12

CONTENTS

4 December 2012 | BrakeandFrontEnd.com

1. Two states have passed laws, and more arelooking:

California was the firststate to enact a law reg-ulating copper andother substances inbrake pads. Washing-ton was not far behindwith an even more de-tailed law. Hawaii,New York, Rhode Is-land, Oregon and evencountries are consider-ing their own laws.

2. The new laws targets the “installer”:

Along with manufacturing and distribution, theCalifornia and Washington state regulations usethe term “installer” (not the most flattering term)in the law’s language. This means a shop in thesestates could be fined $10,000 fine per violation if anon-approved brake pad is installed.

3. The laws target other harmful substancesin brake pads:

While copper has gotten most of the attention,these new laws target asbestos, chromium andother heavy metals in brake pads that harm na-ture and technicians.

4. These laws are being phased in NOW:

While these laws will not be in full effect formore than 10 years, many components of thelaws are being phased in as you read this. By Jan-uary 1, 2013, friction material manufacturers whodo business in Washington state are required tosubmit a report on their use of copper, nickel,

zinc, antimony and othermetals. By 2015, all newinventory must be labeled saying if it complies with the law.Manufacturers, distribu-tors and “installers”have 10 years to sell offexisting inventory. InCalifornia, the law alsorestricts the use of thecadmium, chromium,

lead and its compounds on January 1, 2014.

5. It might impact your choices for brakepads:

The laws do put new financial and technicalburdens on friction material manufacturers.Under the Washington state law, friction materi-al formulation has to be tested by an approvedlaboratory and the applications that use this ma-terial must be submitted so the right label canappear on the box. Every step in the processcosts money and time. These burdens may be sogreat that some manufacturers could get out ofthese markets completely.

Like it or not, this could be our generation’sasbestos. We are just at the start of what couldbe a painful, but necessary process that willimpact your shop and the environment in apositive way even if you do not live on theWest Coast. It is my opinion that these newrequirements will improve the pads you areinstalling on a vehicles. More to come. �

FIVE THINGSTO KNOW ABOUT BRAKE PAD COPPER LAWS

brake pad testing at Link Engineering

Viewpoint By Andrew Markel


Do you remember when you played the game

of “telephone” as a child, and the original

information being conveyed was often to-

tally different by the time the last kid commented?

The same thing can happen with a vehicle prob-lem when more than one person is involved in get-ting the information to the person at the end of theline. And who’s usually at the end of the line? Thetech.

Second-hand information can be misleading,even totally wrong. There’s always a chance itmight be correct, but I wouldn’t count on it. It depends on where that information originated.

A few weeks ago, I had a problem come upregarding the condition of a car that was for sale. Itwas a low-mileage car, and had been sitting in agarage for nearly eight years without much atten-tion. The owner’s father-in-law bought the car newbefore he passed away. The rest of the family hadinformed the son-in-law that everything was intiptop shape. It definitely was clean, dent free, thepaint still looked great and there wasn’t a blemishon the interior.

As with any of these “moth-balled” cars, thefirst thing that was an issue was the battery. Whena battery sits for that long, it’s natural for it tobecome sulfated. So, the owner had it towed to ashop to have the battery replaced.

After the new battery was installed, it took a fewcranks for the engine to start. After a few coughsand shudders, the engine purred like new, but theservice light was on. (This seemed to be the majorconcern for both the seller and the buyer.) But, bythe time the car arrived at my shop, the enginecodes had been cleared from the PCM by the tech.All I had to go on was the second-hand informa-tion that the owner overheard from the tech whohad worked on the car.

“The mechanic told me it might need a tune-up,or something,” the owner proudly tells me.

It’s that “something” that bothered me. A tune-up, maybe, or I’m thinking it might be old gas, butwhat’s a “something”? It really doesn’t matter atthis point as the buyer jumps into the conversationand says, “Do a complete checkup for me, and letme know if it’s worth what they want for it.”

There were numerous small problems to dealwith, and a few major issues as well — everythingfrom an ABS light staying on (which neither partymentioned), to a very poorly repaired alternatormain positive lead.

With the car in the service bay, you could hearthe alternator whine grow louder and louder thelonger the car ran. What I did find was thatbetween the alternator and the battery there was alarge, homemade connection that was hot enoughto fry an egg on. This was causing a rather largevoltage drop.

After explaining the ABS problem, the A/C andwiring issues, and all the other problems I foundwhile checking it out, it was clear to me they werenot going to purchase the car.

Needless to say, before I could show the ownerany of the results, I had a very upset individual atthe service counter.

“I was told everything was in perfect workingorder,” the buyer shouts at me.

“Do you want to see what I found out? It wouldbe a lot easier to show you,” I told him.

As I showed him the actual conditions, what hewas told regarding the condition of the car cameinto question. It was only then that he knew heshould have had a tech check it out, rather thanrelying on the second-hand information providedby the family.

Digging through the maze of hearsay informa-tion is what a professional technician does everyday. And people will always interpret what any-one says into what they “thought” they heard,making our job as a professional tech communicat-ing repair issues even more difficult. �

By Scott “Gonzo” Weaver [email protected]

Gonzo’s Tool Box

SECOND-HAND INFORMATIONWhen Critical Details GetLost in Translation

v

The Automotive Aftermarket Products Expo

(AAPEX) opened with a colorful splash of orange

and ended on a similar celebratory note with an

increase in the number of exhibitors and exhibits

at the 2012 event. AAPEX was held Tuesday, Oct.

30 through Thursday, Nov. 1, at the Sands Expo

Center in Las Vegas, Nev.

The 20th anniversary event opened with a per-

formance by the Foothill High School Drum Line

of Henderson, Nev. The performance was fol-

lowed by an Orange Crush of members of the

Automotive Warehouse Distributors Association

(AWDA) wearing bright orange shirts with the

AWDA logo, as well as the logo of the program

group or distributor organization to which they

belong.

The show floor featured 660 first-time

exhibitors, and a total of 2,309 exhibitors, up

from 2,292 in 2011. Exhibitors occupied 5,054

booths, compared to 4,984 last year. The number

of verified buyers at Automotive Aftermarket

Industry Week (AAIW), which includes AAPEX

and the SEMA Show, reached 60,000, up slightly

from 59,700 the previous year. Pre-registered

buyer numbers exceeded 64,000, down 2.7 per-

cent over 2011. International buyers traveled from

more than 130 countries to attend Industry Week.

In addition, the AAPEX Learning Forum offered

an extra day of education in 2012 to better accom-

modate attendees’ schedules. A total of 32 ses-

sions were presented on a range of topics includ-

ing sales, marketing, branding, warehouse distrib-

utor management, industry trends, employee pro-

ductivity, technology and service readiness.

Attendees gave high marks to sessions and speak-

ers, specifically the content of the sessions and

being able to apply what they learned when they

returned to their businesses.

AAPEX is the premier event for new products,

business solutions, the latest innovation, extensive

education and exceptional networking. The 2013

AAPEX will take place Tuesday, Nov. 5 through

Thursday, Nov. 7, at the Sands Expo Center in

Las Vegas, Nev.

AAPEX 2012 Opens And Closes On A High Note

Industry Review

GUESS THE CAR! WIN $50!

Employees of Babcox Media, industry manufacturers and Brake and Front End advertisers are not eligible to enter.

What vehicle MAKE does the picture on the left represent? Submit your guess with our online contest form by visitingwww.BrakeandFrontEnd.com/guessthecar

The winner will be randomly selected from correct entries and awarded $50. Entries must be received by January 1, 2013.

November Solution: Lincoln NavigatorSolved by: Shaun McKelvin of McKelvin and Sons Inc.in Camden, AR.

CONGRATULATIONS SHAUN!

#9

#10

Industry Review


Navy Veteran FindsBusiness Success WithMeineke Car Care CenterIn May, Navy veteranTom Perez purchased aMeineke Car CareCenter location inPensacola, Fla., with thehelp of Boost A Hero, acrowdfunding site tohelp veterans open fran-chises. Perez raised$6,740 through Boost AHero, and Meineke dis-counted the franchisefee and provided additional financing, making itpossible for Perez to take over the Pensacolalocation.In his first six months in business, Perez, 31, hashired five veterans, keeping his promise to helpother veterans find jobs. He also has increasedsales for his location by 60 percent, and he hopesto open a second center. Perez has been nominat-ed for the International Franchise Association’s (IFA)Veteran of the Year award and is a finalist for theU.S. Chamber of Commerce’s Hiring Our Heroesaward. “When I was forced to leave the Navy after 10

years of service due to downsizing, I tried to find ajob as a police officer. I had served as master ofarms and was a decorated veteran, but I couldn’tfind a job,” Perez said. “I looked into opening afranchise and Meineke was clearly a great businessopportunity. The skills I learned in the militaryhave been a key part of my success, and I’m look-ing forward to continuing to grow my business.As I grow, I’ll be able to hire even more veterans,which is something that is important to me.” Perez completed four tours in Iraq and manytours in other locations. He received fourNavy/Marine Corp Achievement Medals, theDefense Meritorious Service Medal, the JointService Achievement Medal, the Navy UnitCommendation, Meritorious Unit Commendation,three Good Conduct Medals, the National DefenseMedal, the Iraq Campaign Medal, the Global WarOn Terrorism Service Medal, the Global War OnTerrorism Expeditions Medal and the OutstandingVolunteer Service Medal.

One year since the launch of DRT, NUCAP continuespushing to meet the needs of its customers and furtherimproving the performance and value of their vehicles.NUCAP marks the one year anniversary of the DragReduction Technology (DRT) brake hardware system

with the release of 17 new kits for more than 90 models

of Toyota, Volkswagen, Dodge, Chrysler, Hyundai,

Chevrolet, Ford, Kia and more.

In order to meet the stricter CAFE regulations, someoriginal equipment brake systems began incorporatinghardware designs to reduce brake drag. In addition toimpacting fuel economy, reducing brake drag has alsobeen shown to reduce brake noise, decrease pad wear andenhance vehicle performance, which is good for the envi-ronment and your budget. NUCAP DRT brings this tech-nology to the Aftermarket to provide this benefit to thelarge population of vehicles currently on the road thatwere not built with these hardware improvements. With more than 60 references servicing hundreds of

applications, NUCAP DRT eliminates unnecessary drag

with a cost effective and easy to install, patent pending,

design. For more information, contact NUCAP at

www.nucap.com.

NUCAP Industries Announces NewCoverage For Drag Reduction Technology(DRT) Brake Hardware System

Honeywell Friction Materials has introduced a new,enhanced online catalog for the Bendix brand, whichallows users to input the VIN to find the appropriatepart number. Honeywell Friction Materials improved its user e-cat-

alog experience after conducting qualitative researchand securing comprehensive feedback from customers. Now, users are able to easily access a search function

from anywhere on the Bendix website. After enteringthe VIN into the search, users will be directed to apage with the exact Bendix part recommended forthe vehicle, with specifications and a link to a trou-bleshooting video. Having this comprehensive infor-mation available saves time and helps eliminate theneed for a phone call with a rep or distributor, accord-ing to Honeywell. These new upgrades come on the heels of several e-

catalog enhancements Honeywell Friction Materialsmade earlier this year. In May, the company put a sys-tem in place so that industry standard-formatted filescan easily be generated for all of its customers. Thecompany also launched the Bendix catalog app forsmartphone users, allowing repair shop techniciansand do-it-yourselfers to look up parts information andaccess images and product specs with the touch of abutton. According to Honeyewell, the e-catalog initiative, a

major focus for the company in 2012, is part of thenew Bendix website rollout, which has been designedwith a simple interface that helps users quickly findwhat they’re looking for. The new site is set to launchthis November. “We designed the part search function to be an indis-

pensable tool and not just a repository of information,”said Grif Jordan, product marketing manager atHoneywell Friction Materials. “The content is con-nected to mimic the technician’s workflow. Afterthey identify a part, any additional Honeywell alter-natives reflecting either greater value or performanceupgrades compatible with their search are listed toprovide even greater product selection. Users willalso have the appropriate ordering detail, any specificinstallation notes, links to troubleshooting trainingvideos and even third-party forum discussions on theproduct collected for them without having to gosearch additional sites or navigate through exhaustiveasset libraries to find the right detail.” �

Industry Review

Honeywell FrictionMaterials' Enhanced OnlineCatalog Offers New VINLook-Up Feature



Kim Brant, an automotivetechnician at Joe’s Tireand Auto Service, St.

Joseph, MO, has been namedthe 2012 Best Tech, sponsoredby WIX Filters.WIX Filters, a member of the

Affinia Group family ofbrands, in conjunction withBrake & Front End, ImportCar

and Underhood Service maga-zines, named Brant the second-annual WIX Filters Best Techduring the annual AutomotiveWarehouse DistributorsAssociation (AWDA) Meetingand Conference in Las Vegason Oct. 29. As part of hisaward, he and a guest traveledto the Automotive AftermarketProducts Expo (AAPEX) for anall-expenses paid trip to Las Vegas.“From the diagnosis of electrical problems to

evaluating exhaust systems to recommendingthe best parts — technicians play a major role inenhancing a vehicle’s performance,” said MikeHarvey, brand manager for WIX Filters. “We arethrilled to recognize Kim Brant for the second-annual Best Tech award for his distinguishedcareer built on outstanding customer service as acommitted advisor and resource, and for hisdedication to learning as vehicles become moresophisticated with a wider range of repairs andmaintenance work.” Brant, an ASE Certified Master Technician and

a WIX Expert-Level Certified tech, said he was

thrilled and humbled to receive the honor ofbeing named a Top Tech.

“With complicated systems that make upautomobiles today, it is imperative that techni-cians provide the highest-quality service toensure that drivers and passengers are safe onroadways,” said Brant. “I am truly delighted towin this award not only for myself, but foreveryone at Joe’s Tire & Auto Service. Fromour technicians, owners to service writers, wehold the shop to the highest standards byencouraging ongoing education, implementingtop-level industry standards and providingexcellent customer service, which drivesreturning customers.”

Techof theYear

Best Tech Finds theSky’s not the Limit WHEN IT COMES TO FINDING NEW CUSTOMERS, KIM BRANT LOOKS OUTSIDE THE BOX

Techof theYearBrant, who has been in the

automotive and repair serviceindustry for 28 years, was a runner up in the 2011 Best Techprogram last year. He’s workedat Joe’s Tire and Auto(www.stjoeautoservice.com) forabout four years, and before thatserved as a technician in a fewlocal dealerships and tire stores.

Besides his exceptional cus-tomer service, Brant has beenactive in his community’s youthorganizations and local technicalschool. He also is credited for hispenchant to go the extra mile togain a new customer for Joe’sTire and Auto Service, an inde-pendent repair shop that hasbeen servicing the St. Josepharea since 1984.

“My biggest enjoyment fromthe auto industry is the chal-lenge of determining the vehiclefailure and taking that processclear through to returning thevehicle to the customer, properlyrepaired,” he said.

Brant, whose own “fleet” ofvehicles includes his daily drive,a 1999 Dodge Grand Caravan,also owns a 1988 GMC 1500 4x4and a 1966 Dodge Dart GTConvertible. His love of vehiclesdeveloped at an early age

through his father’s business. “My father owned a Mobil

service station from my infancyto my teenage years,” Brant said.“Without his involvement in theautomotive world, I’m sure that Iwould not be involved myself.”

One of the most unique jobsBrant had seen as a technicianhad to be the servicing of an A/Csystem on a local Life Flight hel-icopter that had been grounded.Since the law requires the A/Csystem to be in working orderfor the helicopter to be used formedical purposes, Brant wasasked by his shop owner if hecould fix the helicopter’s A/Csystem since the company thatpreviously serviced the craft was

no longer in business. Although he had never

repaired a vehicle that isdesigned to leave the ground,Brant hit the Internet to researchthe helicopter’s HVAC system,grabbed his tools and headedout to Rosecrans MemorialAirport, where he was greetedby the Life Flight air staff. After servicing the A/C system

successfully, Brant said he wasconfident he would be contactedto service the system if it everneeds it in the future.

Brant said he was happy to beof assistance in the Life Flight’sreturn to the skies, and thattoday’s shop’s can find business“outside the box.”

“I’ve worked on a lot of uniquevehicles — from Ferraris toLamborghinis to Prowlers — butnot many techs in this businesscan say they have worked on ahelicopter.”And not just any helicopter, but

a Life Flight helicopter. �


RUNNERS-UPWIX Filters and Babcox Media alsonamed two 2012 Best Tech finalists: Travis Luscomb from Larson’sService, Inc. in Peabody, MA, andKevin Dietz from BTS Tire andService in Providence, RI.

COMMUNITYINVOLVEMENTIn addition to his service as anautomotive technician, Brant alsowas recognized for his communi-ty service that includes:• Raising money for Habitat forHumanity;• Raising money for the SpecialOlympics; and • Participating in NeighborhoodBeautification programs andrecycling efforts.

NAPA is the handy place to getgifts for a handyman this season.Starting November 18th, stopinto a participating NAPA AUTOPARTS Store and pick up aGearWrench 7-piece RatchetingWrench Set — in standard ormetric — for just $29.99. Or, aCrescent 5-piece Locking PlierSet, just $26.99. Promotion ends12/31/12, while supplies last.www.NAPAOnline.comCircle #91 for information

91

With an estimated 60% of vehicles on the road in need of an alignment, Hunter Engineering Company devel-oped the new Quick Check system to help shops quickly identify these vehicles and drive more traffic to the

alignment bay. Quick Check captures toe and camber measure-ments and produces printed results in under a minute. Servicewriters can then use the easy-to-understand, color-coded printoutsto alert customers of misalignment issues and generate more re-pair orders for alignment service.Circle #90 for information

Using the Bartec Tech400SD TPMS tool, technicians can program new TPMSsensor IDs on GM and Ford vehicles through the OBDII connection. With theTech400SD, a technician can use the same easy 3-step procedure of “Capture,Connect and Program” for GM and Ford models equipped with direct TPMS.Equally important to ease of use is process training. For example, using theTech400SD, the relearn process is the same on a Toyota Camry as it is on aChevrolet Impala. That means learning only a single method of repair on a domestic and imported vehicle.Circle #94 for information


Federal-Mogul has added 36 parts,including 14 new control arms, to itsline of MOOG Steering and Suspen-sion components. According to Feder-al-Mogul, as the automotive servicemarket’s “Problem Solver,” theMOOG brand offers innovative prod-uct designs that help ensure en-hanced performance and durabilityand easier installation. The latest ex-pansion of the MOOG line includes14 new control arms for a wide rangeof foreign nameplate and domesticapplications.Circle #92 for information

Tenneco’s Monroe Brakes brand now offers a portfolio of ad-vanced braking solutions tailored to the needs of significantly moreconsumers. New Monroe ProSolution brake pads – positioned as apremium technology available at a mid-range price – complementthe company’s popular Total Solution offering of Monroe Ceramics and Monroe Dynamics ultra-premium pads in aprogram designed to help distributors, jobbers and serviceproviders increase their shares of the brake repair market.Circle #93 for information

Product Showcase

90

94

92

93

Brought to you by:

AutoCareProNews.com


Brake Job TOYOTA

ToyotaBrake Tips

SIX, SIX OR FIVE: ORDERINGTACOMA BRAKE PARTSPREPARATION

1995-2004 TACOMA

When ordering parts for a V6 model, makesure you tell your parts supplier if you areworking on a Pre-Runner or 4WD model. Thecalipers may look the same, but there are dif-ferences in the pads and rotors. Some electron-ic catalogs have trouble telling the difference.

REPLACE THE BRAKE HOSE IF THECALIPER HAS OVER HEATED

If you are replacing a caliper that has lockedup and created a great deal of heat, youshould also replace the brake hose. This is agood practice anytime, but particularly impor-tant with the Toyota line as there have beensome instances of the hose failing at thecaliper fitting after being subjected to theextreme heat.

RUNOUT REMEDYAll Models

You can lower the runout by changing theposition of the rotor on the hub flange. Withthis technique, you can minimize the amountof material removed from the rotor during on-the-car machining. This can make a more ther-mally stable rotor that absorbs heat evenly andreduces pulsation comebacks.

REAR AXLE LOAD VALVE LOWPEDAL1995-2004 TACOMA

One problem area is the load-compensatingvalve that attaches to the rear axle. The

HERE ARE THE TOP TOYOTABRAKE TIPS THAT CAN SAVEYOU FROM A COMEBACK ORLOST PRODUCTIVITY.

mechanical linkage and thevalve causes problems on sometrucks by leaking and increasingbraking distances. The main cul-prit is rust and corrosion. Thevalve is designed to changebrake hydraulic pressure in therear brakes as the load changesthe relationship between thebody and axle. Some technicians

have reported the spare tire cancome in contact with the linkageif the carrier mounting pointsfail due to corrosion. Whenreplacing the unit, it is critical toadjust the linkage. Make surethere is 78 mm of distancebetween the center of the bolt onthe axle shackle and the centerof the bolt on the arm that con-nects the linkage to the valve for2WD trucks and 120mm for4WD trucks.

ALL HYBRIDS:DEACTIVATING HYBRIDSYSTEM

If you are replacing calipers orother hydraulic components on aPrius or other Toyota Hybrid,you will have to deactivate thesystem with a scan tool. Most

scan tools will walk you throughthe process that involves remov-ing the two ABS pump relaysand pumping the pedal in asequence to depressurize the sys-tem. The system can also bedeactivated by waiting for twominutes after turning the powerswitch OFF, stopping the brakepedal operation and closing thedriver door before removing thetwo relays for the ABS system.Also, it is a good practice whenworking on vehicles withadvanced ABS and StabilityControl systems to remove thekeys from the vehicle and placein a different room, like at thefront counter. Also, it may takeat least five minutes for the car togo into a sleep mode.

PRE-2005 TUNDRA OFF-THE-SHELF BRAKEUPGRADE

It is possible to upgrade thebrake system on some pre-2005Tundra trucks using off-the-shelfparts. An upgrade was engi-neered and information was pro-

Brake Job TOYOTA


vided through a service advisory,as production changes added alarger caliper system in front anddisc brakes in the rear to substan-tially improve braking perform-ance, while reducing the incidenceof pulsation complaints. Thisupgrade became the standardbrake system on late 2005 truckmodels.

While some of these truckswere updated under warranty,others have been transferred tonew owners and the problemsshow up again as these new own-ers subject them to heavier-dutyuse. That’s where this updatebecomes an opportunity for inde-pendent repair shops to educateand earn the trust of owners ofthese vehicles.

Brake Job


HYBRIDS: BRAKE PADCONSIDERATIONS

The Prius has unique require-ments for the brake system. On2001-2004 models, the hydraulicbrakes were not used until thevehicle was below 7 mph or ifthe vehicle had to make a hardstop. Later models use a moresophisticated system that mayengage the brakes at higherspeeds.

The majority of the time, thepads never reached conventionaloperating temperatures and cor-rosion could occur between thebacking plate and friction materi-al due to the fact that the padsnever dried out. On some vehi-cles, the corrosion between thefriction material and backingplate would cause a completeseparation. Always use a high-quality pad for hybrid applica-tions to avoid problems. It is nota question of better performance.It is a question of quality andengineering.Since it is impossible to perform

a conventional break-in/beddingprocedure on the test drive, makesure the manufacturer promisesexcellent performance right outof the box. Also, applying a non-direction finish with a ball hone

will help the new pads evenlydeposit a layer of friction materi-al to the new rotor.

HYBRID: PRIUS BRAKENOISE FROM PEDAL

Some 2004-07 Prius Hybridsmay produce an annoyingsqueaking sound when the brakepedal is applied or released.Toyota says the noise is mostaudible when the key is in theReady mode with the vehicle notmoving. A defective brake actua-tor assembly is the likely culprit.

Before condemning the actuator,however, try bleeding the brakesystem. If the noise goes away,you’re done with the fix. If thenoise remains after getting outthat last belch of air, replace thebrake actuator with an upgradedunit, Part No. 44500-47090. �

Brake Job TOYOTA


Stee

ring

Ang

le S

enso

r (S

AS)

:On

Minis without Electronic Stability Control

(ESC

or DSC

), SA

S is not installed. Reprogramming

the sensor on ESC Minis requires an enhanced scan tool

that can com

municate with the ABS and BCM modules.

Alig

nmen

t Sp

ec2002-2

006 M

INI

CO

OP

ER


SP

ON

SO

RE

D B

Y

Fron

t C

amb

er o

r C

aste

r: There are no built-in factory

adjustments for front camber or caster. The only way to

adjust these angles is to purchase adjustable upper strut

mounts. These kits can typically adjust cam

ber by ±2.00º

and caster by ±0.75º.

Rea

r To

e:Rear toe is adjusted by an

eccentric bolt and plate that secures the

lower transverse link to the trailing arm.

The rear toe and cam

ber angles on the

Mini have a considerable amount of

cross-talk. If the rear camber is in

spec but at the fringes, a toe

adjustment could push it over

the edge. Also, check ride

height before doing a drastic

adjustment.

TPM

S:The first-generation Mini has two TPMS system

s and one

reset procedure. The base system

is an indirect system that works off

the wheel speed sensors. The optional system is a direct system that was

an option and often standard on cars with run-flat tires. To reset these sys-

tems, switch the engine off and the ignition on, press the "Set" button and

hold (approx. 6 seconds) until the words "Set tire pressure" appear in the

instrument cluster (instrument cluster high) or the yellow LED

lights up

(basic instrument cluster).

Bus

hing

s:The Mini uses four hydraulic bushings.

In the front, the hydraulic bushing is located at

the rear of the control arms. In the rear, the

hydraulic bushing mounts the trailing arm

to the body. These mounts can leak when

they fail. The cam

ber and toe

will change when the

bushings go soft.

BMW recom

-mends replacing

the bushings in

pairs.

Rea

r C

amb

er: The rear

camber is not adjustable. If

the rear cam

ber needs to

be adjusted, it requires

replacement of the lower

control link with an

adjustable part.

Oxygen Sensor Internal View


An oxygen sensor ismade of ZirconiumOxide (ZrO2), a chemi-

cal compound used to form thesensor’s thermal-driven electro-chemical fuel cell. The Greek let-ter Lambda is used to describethe voltage range of the sensorwhen it compares the quantityof oxygen in the exhaust relativeto oxygen in the atmosphere.Two Platinum (Pt) electrodes areplaced on the ZrO2 to provide aconnection for output voltage toa control module.

A Planar Air Fuel Sensor is acombination of a standardZirconium Oxide Oxygen sen-sor and a Pump Cell to main-tain a constant sensing of a sto-ichiometric air fuel ratiothrough the extreme rich andlean conditions. The pump cellis a diffusion gap in theZirconium Oxide of the sensorthat is connected to a controlcircuit.

The pump cell controls theoxygen concentration of thesensor by adding or subtractingoxygen to the diffusion gap.Input to the electronic circuitmodifies the oxygen concentra-tion by changing the polarity ofthe current flow in the pumpcell. The changing polarity ofthe input and trim current flowcauses the control circuit tosend a rich or lean signal to theengine control module.

How long should anoxygen sensor last?

An oxygen sensor should out-last the vehicle emissions war-ranty. With proper powertrainmaintenance, it is possible for

the sensor to last the life of thevehicle, which could be inexcess of 250,000 miles.

When does an oxygensensor need to bereplaced?The service engine soon light

will come on and a diagnostictrouble code(s) will be stored.There may be multiple codesstored for a sensor. A fueldelivery malfunction can be thereason for an oxygen sensor tofail.

Do oxygen sensorsdegrade over a period oftime?

Simple answer: Yes. Whatcauses an oxygen sensor todegrade? When silicon was aningredient in RTV and coolant,the silicon could cause the sen-sor to rapidly degrade. It wasreferred to as silicon poisoning. Sulfur can cause the degrada-

tion of an Oxygen sensor andthe concentration of the Sulfurin the gasoline will determinethe rate at which the sensorwill degrade.

Motor oil contains phospho-rous, and zinc also cause thedegradation of the sensor whenexcessive oil vapor is intro-duced through crankcase venti-lation.

What can cause anoxygen sensor to fail? The most vulnerable part is

the wiring and connector. Next is the heater. Its func-

tion is to bring the sensor tooperating temperature duringcold starts and engine warmup. It can be damaged by ther-mal shock.

Does overall engine main-tenance affect the life ofan oxygen sensor?Simple answer: Yes. An

important maintenance item isthe oil change. It contributes tothe life of an oxygen sensor.Positive Crankcase Ventilation(PCV) can contribute the degra-dation of the oxygen sensor.Vapors from contaminated oilin the crankcase can shortenthe life of an oxygen sensor. �

O2 Sensor


2012TPMS TSBs

FORDTSB Number: 12-6-2Vehicles: 2009-2011 FordEdge and Mercury MKX

Condition: Corrosionand on the lip of 22-inchrims and whiskers/ventson the tire’s bead seatmay cause the TPMS toilluminate.

Solution: Disassemble the rim and tire andclean the rim and tire bead seats with a ma-roon Scotch-Brite pad.

GMTSB Number: 00-00-90-002KVehicles: All GM Vehicles with direct TPMSsystems.Subject: Adjusting tires under warranty.This TSB is an advisory stating that adjust-ment of tire pressures is not a warranty proce-dure. It also defines a cold tire as one settingfor at least three hours. It also advises againstthe use of non-GM tire sealants.

TSB Number: 05-03-10-020DVehicles: All GM vehicles with TPMS.Subject: Nitrogen in tires.

This TSB is an update of a TSB issued in2010 on the use of nitrogen in tires. This TSBdoes not endorse nor advise against the useof nitrogen in tires. But, the TSB does makesome caveats. It does describe the “theoreticalbenefits” of nitrogen, but it also says that it isdifficult to obtain nitrogen in a purified statethat could deliver the benefits in the field. Ifyou read between the lines, this TSB says:“GM vehicles are designed to work withatmospheric air, but nitrogen can benefit thedrive if the purity of the nitrogen is kept.

INFINITITSB Number: 12-29Vehicles: All Infinitimodels with TPMS.Subject: Damage toTPMS sensors

Infiniti pulls nopunches here! Theluxury brand ofNissan tackles two ofthe leading causes of

THE TOP TSBS FROM ALL THE OEMS ON TPMS SERVICE ISSUES.

Tires

sensor damage. Infiniti tells tech-

nicians that deepwell, long reachair chucks canbreak and bendstems. It evenadvises againstthe use lockingchucks. The TSBrecommends theuse of shallowchucks withoutextensions.

While someOEMs have stated that some sealants are compat-ible with sensors, Infinity states that somesealants and propellants can crack the housing ofsensor. The pictures in the TSB are hard to dis-pute.

TSB Number: 12-046AModels: 2013 JX35Subject: TPMS registration procedure.

This TSB is of little consequence to technicianswho use an aftermarket scan tool to register IDswith the TPMS module. The procedures dis-cussed concern new hardware and software forthe CONSULT III scan tool.

JAGUARTSB Number: JTB-001654Subject: Loss of pressure during inflation.

Jaguar issued this TSB to advise technicians tobe careful with valve stems during inflation orvalve cap removal. The TSB advises stronglyagainst metal valve stem caps that can cause gal-vanic corrosion. It also advises that if the cus-tomer has used non-approved valve caps, that allfour or five sensors should be replaced.

LEXUSTSB Number:SB-0042-12SB-0055-12SB-0056-12SB-0073-12SB-0082-12SB-0083-12SB-0085-12SB-0100-12

Subject: Sensor activation on 2013 models.

Dealer pre-delivery activation procedure to wakeup the sensors. No use for in-service vehicles.

MAZDATSB Number: 02003-12SUBJECT: Activation of sensors.Model: 2013 CX-5

Tires

This TSB describeshow the TPMS sys-tem operates and howto service the system.Instructs technicianshow to relearn sensorpositions and possi-ble symptoms for aproblem.

MITSUBISHITSB Number: 12-31-001Models: All Models with Direct TPMS from 2004-2012SUBJECT: TPMS General Service Procedures

This 11-page TSB outlines how to service anddiagnosis Mitsubishi vehicles equipped withTPMS. This is one of the most complete TSBsever published. This is a must read that shouldbe printed out.

NISSANTSB Number: 10114BVehicles: All Infiniti Models With TPMSSubject: Damage to TPMS sensors

Nissan pulls no punches here! Nissan tacklestwo of the leading causes of sensor damage.

The OEM tells technicians that deep well, longreach air chucks can break and bend stems. Iteven advises against the use locking chucks. TheTSB recommends the use of shallow chuckswithout extensions.

While some OEMs have stated that somesealants are compatible with sensors, Nissanstates that some sealants and propellants cancrack the housing of sensor.

SCIONTSB Number: SB0001-12Subject: Inflation pres-sure temperature com-pensation.

Scion released this TSBto inform technicianshow ambient tempera-tures can influence tirepressure. The release

includes a chart that plots temperature and pres-sure. This TSB will help you determine the cor-rect tire pressure in all seasons. SB0001-12 isanother “must print” TSB for technicians.

VWTSB Number: 4412-02Models: 2012-2013 CC

This TSB informstechnicians that someCC models mayexperience a loss ofsignal from a singleor multiple TPMSsensors. The onlysolution is to replaceall four sensors withupdated sensorsfrom HUF. �

Tires



Tech Tips FORD / BMW / SUBARU / HONDAThis month is sponsored by:

The chassis group at Affinia Global Brake andChassis – the makers of Raybestos chassis parts –have one thing to say when it comes to memorysteer… FORGET ABOUT IT!Memory steer may occur when replacing upper

and lower ball joints on a Ford F250, 350 or 450with a Dana 60 axle.

There are three major factors that can lead tomemory steer:

• Not removing and cleaning the camber/castersleeve so it can move freely during the installa-tion;

• Improper use of the ball joint press; and• Not using the torque wrench properly or fol-

lowing the proper 1-2-3 torque sequence.

Fortunately, memory steer can be easilycorrected. The repair procedure is as fol-lows, using P/N 500-1048 (Upper BallJoint) and P/N 500-1181 (Lower BallJoint):

1. Remove steering knuckle. 2. Remove upper and lower ball joints from

knuckle using a ball joint press and adaptors. 3. Inspect steering knuckle for damage. Clean

dirt, rust and burrs from bore and recess, includ-ing recessed area into which the ball joint flangefits. (Figure 1)4. Place the new

ball joint in a viseto articulate studand rotate. Pre-lubricate thejoints at this time.Install upper andlower ball jointsinto the steeringknuckle using aball joint pressand adaptors making sure the adapter fits theouter flange area. (Figure 2)5. Before installing the knuckle assembly in

yoke, index camber/caster adjustment sleevebefore removing and cleaning. It is important

that the sleeve moves freely in the axle yoke.(Figure 3)6. Install

knuckleassemblyinto the yoke.(Follow thetorquesequencenoted belowto ensure aproper instal-lation.)Torque thelower ball joint. Make sure caster/camber adjust-ment sleeve moves freely. Torque the upper balljoint. Re-torque the lower joint.

Torque sequence:1. Lower Ball Joint (35 ft-lbs) 2. Upper Ball Joint (70 ft-lbs)3. Lower Ball Joint (190 ft-lbs)

A video showing the complete process for cor-recting memory steer can be found on theRaybestos brand channel of YouTube:http://www.youtube.com/watch?v=SKChabX19YA.For more information on additional chassis solu-

tions or other Raybestos brand brake or chassisparts, visit www.raybestos.com or call 800-323-0354.Courtesy of Affinia Global Brake and Chassis –

the makers of Raybestos.

FORD: F250 & F350 Memory Steer Solution

Figure 1

Figure 2

Figure 3

Tech Tips BMW / HONDA / SUBARU

The customer may complainthat the electric power steer-ing is not working properly.

Vehicle Application: 2003BMW Z4 2.5L and 3.0L, and2004 Z4 2.5L

Customer Concern:The electric power steeringis not working properly. Potential Causes: Defectiveelectric motor power steering(emps), blown fuse or dam-aged wiring harness.

Tests/Procedures:1. The electric power steer-ing system on this vehicle is aone-piece unit that has thecontrol module and the powersteering assist motor.2. Check for proper powerand grounds at the module.Fuse 22 and fuse 64 both feedthe assembly. They providebattery voltage on the red

wire and the green/white wire.3. The brown wire should bechassis ground.4. Other wires are for com-munication and a signal fromthe steering angle sensor.These values can be checkedin the datastream of a scantool, but should not be aproblem if there are no relat-ed codes stored for them.Cause: The power steering

assembly should always have acentering clip installed on theshaft whenever it’s removedfrom the vehicle. Onceinstalled, the clip can beremoved. A new moduleshould have the clip installed; ifnot, return the module and getanother one. Never install aused one because they will notbe centered and clipped prop-erly. New modules also requirecoding and steering angle ini-tialization after installation.Courtesy of Identifix.


REAR ROTOR RUBBING ON BACKINGPLATE AFTER INSTALLATION

BMW Electric Power Steering Is NotWorking Properly

On some Subaru, Honda andother vehicles utilizing a“Drum-in-Hat” type parkingbrake system operated in acorrosive environment (roadde-icers, salt, etc), the new rearbrake rotor may rub againstthe backing plate. This condi-tion may be caused by corro-sion between the backing plate and knuckle assembly that has “jacked”the backing plate away from the knuckle such that it makes contact withthe brake rotor. While some may machine/grind the inboard-most edgeof the parking brake drum, the correct course of action is to disassemblethe parking brake, remove backing plate from knuckle, thoroughly cleanall components (replace parts as necessary) and reassemble. �Courtesy of Centric Parts www.centricparts.com

DI R E C T C L A S S I F I E D S

BrakeandFrontEnd.com 35


ERIKSSON INDUSTRIES • 800-388-4418Old Saybrook, CT • FAX 860-395-0047 • www.erikssonindustries.com

Audi • BMW • JaguarRange Rover PorscheNavigator • Saab • VW

Filters Valve Bodies Kits • OilsHard Parts Manuals

Torque Converters

AuthorizedDistributor

Transmissions/Parts

Used/New AutomotiveEquipment

1-800-223-2573www.AllStates.com


Call now to order or to receive a free 2012 catalog 1-800-434-5141www.autobodysuppl ies.com

Why switch to PDQ? PRICES. Low prices. High Quality. Always.1st time buyer? Order from this ad and receive these special prices.

AD INDEX

Advertiser . . . . . . . .Page Number

ADVICS . . . . . . . . . . . . . . . . . . . . . . . . . .19

Akebono Corporation . . . . . . . . . . . . . . .23

APA Management Group . . . . . . . . . . . . .9

Auto Value/Bumper to Bumper . . . .Cover 3

Bartec USA, LLC . . . . . . . . . . . . . . . . . . .31

DEA Products/Pioneer Inc . . . . . . . . . . .11

Jasper Engines & Transmissions . . .33, 34

Mevotech . . . . . . . . . . . . . . . . . . . . . . . . .3

NAPA . . . . . . . . . . . . . . . . . . . . . .5, 25, 27

Nucap Industries . . . . . . . . . . . . . . .14, 22

O'Reilly Auto Parts . . . . . . . . . . . . . . . . .13

Packard Industries . . . . . . . . . . . . . . . . .10

Parts Master . . . . . . . . . . . . . . . . . . . . . .15

Parts Plus . . . . . . . . . . . . . . . . . . . . . . . .29

Performance Friction Corp . . . . . . .Cover 2

Red Kap . . . . . . . . . . . . . . . . . . . . . . . . . .1

TYC/Genera Corp. . . . . . . . . . . . . . . . . . . .7



ECM’s & MAF’s

Call Toll Free1-UPS-OUR-ECMS(1-877-687-326(1-877-687-32677 ))

570-883-9930570-883-9930www.autoecms.comwww.autoecms.com

I f W eI f W eD o n ’ tD o n ’ tH a v eH a v eI t . . . I tI t . . . I tD o e s n ’ tD o e s n ’ tE x i s tE x i s t

AUTOCOMPUTERS

• 325,000 units in stock• All Foreign & Domestics • ECU’s & BCM’s• ABS & Airflow’s• Same Day Shipping• R & R Service • 1-Year Warranty• Free Tech Help on Web• Inhouse Reprogramming:GM, Ford, Jeep & Chrysler

SAVE

70%

AdvertisingRepresentativesThe Tech Group

Bobbie [email protected], ext. 238

Dean Martin [email protected] 330-670-1234, ext. 225

Sean [email protected], ext. 206

Glenn [email protected], ext. 212

John Zick [email protected] 949-756-8835

List Sales Manager Don [email protected], ext. 286

Classified Sales Tom [email protected], ext. 224


Brake Lights


December 1960 — Cashew nutshell liquid or oil is a fluid that isextracted from the nutshell of the cashew nut. The solid form isutilized in the brake friction formulators as friction particles inpads. The cashew nut binds the materials together and changes thecoefficient of friction. Cashews are still used in brake pads today.

brake & front end, dec. 2012

Documents

brake pads gonzo

end issn

reader servicecircle

reader service4

following rates

paid subscriptions

list sales manager don

editor larry carley