TSB: 04-002/99

NOISE FROM FRONT BRAKE CALIPER WHEN BRAKING SLIGHTLY

NOTE: This bulletin replaces P008/96. Please update your records accordingly.

APPLICABLE MODELS

All 1989-98 Protege

All 1992-95 MX-3

DESCRIPTION

When braking at slow speeds, a popping noise can be heard from the front calipers. This noise only occurs in association with wheel rotation (one pop per wheel rotation). This condition is caused by a combination of wear on the caliper main sleeve and the brake disc plate (rotor) being warped.

Customers having this concern should have their vehicle repaired using the following procedure.

NOTE: Be sure not to confuse this concern with a pop noise that occurs only once, sometimes twice, per brake application. This pop noise can usually be reproduced by entering a turn at greater than 20 MPH and then lightly applying the brakes. This noise is considered a normal condition and is caused by the necessary clearances between the knuckle, caliper, and the pads. Any attempt to repair this concern will only result in the noise being eliminated temporarily.

REPAIR PROCEDURE

1. Verify customer concern.

2. Inspect front rotor for runout. Refer to WSM.

• If runout is within specification, proceed to STEP 3.

• If runout is not within specifications, measure the disc plate thickness.

• If disc plate is not within minimum thickness specification, replace it and return to STEP 2.

• If rotor can be machined within specification, machine the rotor using the ACCUTURN On-Car brake lathe or equivalent.

NOTE: The on-car brake lathe MUST mount to the steering knuckle, NOT to the hub.

3. Remove the upper and lower guide plates from the knuckle and adjust the prongs so that the distance between the them is 10.8 mm.

4. Clean the caliper and brake pad slide surfaces with a wire brush.

5. Reinstall the adjusted guide plates and apply a small amount grease to the rubbing surfaces.

6. Replace the main sleeve and rubber seals (supplied with main sleeve) with modified parts.

NOTE: Before installing new main sleeve, apply the grease that is supplied with the modified main sleeves to the outside of the sleeve and inside of the new rubber seals.

7. Mount the caliper assembly to the steering knuckle and tighten the sleeve bolts.

8. Repeat procedure on other side of vehicle if necessary.

9. Verify repair.

PARTS INFORMATION

WARRANTY INFORMATION

NOTE: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.