TECHNICAL SERVICE BULLETIN Bulletin Number 20/03

Passenger and Light/Medium Commercial Issue Date: 31 March, 2003

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Circulate to Service Manager Parts Manager Foreman Receptionist Technicians
x x x

Subject/Concern: BA Falcon Front Brake Shudder ----- “Interim service action only”
Models: All Falcon models from BA Launch with standard brake package.
Summary: Some BA Falcon vehicles may experience front brake shudder / vibration.
Cause: Excessive Lateral brake disc run-out can cause high spots which wear down during non-
braking disc rotation, this creates Disc Thickness Variation (DTV). DTV generates
shudder / vibration when the brakes are applied.
Action: For BA Falcon only – Brake disc must be machined on car. Off car machining of brake
disc is no longer acceptable. Brake pads do not need to be replaced and will not be
reimbursable.
Until further advice, repairs for the specific issue of brake shudder as described in this
Warranty Status: TSB, on the front brakes of BA Falcon equipped with standard brakes only, are
reimbursable up to the limits of the new vehicle warranty (3 years/100,000kms)

Service Procedure
Concern Description:
Analysis should be carried out by road testing the vehicle on a smooth road surface at speed not exceeding 80kph,
decelerating to 20kph. Brakes should be at normal operating temperature, as they DO NOT need to be excessively
hot for this test. Brake shudder symptoms include severe steering wheel nibble, seat or floorpan vibration, fore/aft
shake commonly described by the driver as inconsistent deceleration. If symptoms are present the front disc should
be machined "On car only". No off car machining is acceptable.
Service Action:
1. Place the vehicle on the hoist.
2. Using a marking crayon mark the position of the wheel relative to the wheel studs.
3. Remove the front wheels and check the “disc to hub phase matching”
(Check that the date stamp on the disc is adjacent to yellow paint on the stud.)

YELLOW PAINT

DATE STAMP

Figure 1. Wheel position mark. Figure 2. Disc to hub phase match.

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HUB – DISC CLEANING PROCESS:
1. Remove disc from hub. Refer to Work shop Manual
2. Thoroughly clean with a wire buff any build-up of rust or contamination on the mating surfaces of the hubs
and disc as per Figure 3 and 4.
3. Repeat for other side of vehicle

Figure 3. Cleaning face of hub. Figure 4. Cleaning disc-mating surface.

DISC MACHINING PROCESS:

1. Remove ABS wheel speed sensor from spindle mounting and place aside. This will avoid metal swarth
contamination around magnetic field of sensor. As per Figure 6.
2. Re-assemble the disc to hub ensuring the date stamp and yellow paint wheel stud are aligned. Secure the
disc to hub with the wheel nuts uniformly tightened to 50-60Nm.
NOTE: Disc machining is to be carried-out using “on vehicle machining”. Dealer sites not equipped with “On
Vehicle” machining facilities are to seek-out appropriate sub-let repairer.

NOTE: When machining disc’s, “minimum material only” should be removed from both surfaces of disc.
Brake pads should not be changed unless deemed unsuitable for re-fitment.
Discs should not be replaced unless the thickness is below recommended width of 26mm. Refer to thickness
specification below.

BA FRONT DISC MINIMUM THICKNESS LIMITS

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 Figure 5. Disc thickness measurement.

3. Measure the disc thickness as per Figure 5. If the disc thickness measures below specification, the disc
must be replaced.

Figure 6. Metal shavings on ABS sensor

4. Remove wheel nuts retaining disc to the hub and clean any swarth/debris from mating faces.
Thoroughly clean metal shavings build-up around hub seal and wheel speed sensor mounting hole.
5. Remove pads from calipers clean and resurface.
Clean pad slides. Re-assemble and reset pads as per workshop manual.
6. Assemble ABS wheel speed sensors.
Assemble road wheels ensuring wheel nut tightening sequence and correct nut torque of 95Nm –155Nm.
Impact wrenches should not be used.

Operation Number/Standard Repair Time

Operation Description Operation Number Time
Disc brake -machine on vehicle- both front 2026BT 1.3hrs

Repair/Claim Coding
Warranty Claim Causal Part Condition
Enter 03020 in box "X" of warranty claim to reference this TSB. BAShudder 67

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