Brake & Front End, Dec. 2012

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

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MAGAZINE

BrakeandFrontEnd.com December 2012

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978th Issue, Volume 84, No. 12

CONTENTS

Publication

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ADVERTISING REPRESENTATIVES HOME OFFICE 3550 Embassy Parkway Akron, Ohio 44333-8318 330-670-1234 FAX 330-670-0874 www.babcox.com PRESIDENT Bill Babcox bbabcox@babcox.com 330-670-1234, ext. 217

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VICE PRESIDENT Jeff Stankard jstankard@babcox.com 330-670-1234, ext. 282 Sales Representatives: Bobbie Adams badams@babcox.com 330-670-1234, ext. 238 Doug Basford dbasford@babcox.com 330-670-1234, ext. 255

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12 04 Viewpoint 06 Gonzo’s Tool Box

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

Sean Donohue sdonohue@babcox.com 330-670-1234, ext. 206 Dean Martin dmartin@babcox.com 330-670-1234, ext. 225 Glenn Warner gwarner@babcox.com 330-670-1234, ext. 212 John Zick jzick@babcox.com 949-756-8835 List Sales Manager Don Hemming dhemming@babcox.com 330-670-1234, ext. 286

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

Classified Sales Tom Staab tstaab@babcox.com 330-670-1234, ext. 224

Editor Andrew Markel, ext. 296 email: amarkel@babcox.com Managing Editor Tim Fritz, ext. 218 email: tfritz@babcox.com

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

Graphic Designer Dan Brennan, ext. 283 email: dbrennan@babcox.com

Advertising Director Cindy Ott, ext. 209 email: cott@babcox.com

Publisher Jim Merle, ext. 280 email: jmerle@babcox.com

Circulation Manager Pat Robinson, ext. 276 email: probinson@babcox.com

Circulation Assistant Kim Hedgepeth, ext. 260 email: khedgepeth@babcox.com

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.

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Viewpoint

By Andrew Markel

FIVE THINGS

TO KNOW ABOUT BRAKE PAD COPPER LAWS 1. Two states have passed laws, and more are looking: California was the first state to enact a law regulating copper and other substances in brake pads. Washington was not far behind with an even more detailed law. Hawaii, New York, Rhode Island, Oregon and even countries are considering their own laws.

zinc, antimony and other metals. By 2015, all new inventory must be labeled saying if it complies with the law.

Manufacturers, distributors and “installers” have 10 years to sell off existing inventory. In California, the law also restricts the use of the brake pad testing at Link Engineering cadmium, chromium, lead and its compounds on January 1, 2014.

2. The new laws targets the “installer”: Along with manufacturing and distribution, the California and Washington state regulations use the term “installer” (not the most flattering term) in the law’s language. This means a shop in these states could be fined $10,000 fine per violation if a non-approved brake pad is installed.

3. The laws target other harmful substances in brake pads: While copper has gotten most of the attention, these new laws target asbestos, chromium and other heavy metals in brake pads that harm nature and technicians.

4. These laws are being phased in NOW: While these laws will not be in full effect for more than 10 years, many components of the laws are being phased in as you read this. By January 1, 2013, friction material manufacturers who do business in Washington state are required to submit a report on their use of copper, nickel,

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5. It might impact your choices for brake pads: The laws do put new financial and technical burdens on friction material manufacturers.

Under the Washington state law, friction material formulation has to be tested by an approved laboratory and the applications that use this material must be submitted so the right label can appear on the box. Every step in the process costs money and time. These burdens may be so great that some manufacturers could get out of these markets completely.

Like it or not, this could be our generation’s asbestos. We are just at the start of what could be a painful, but necessary process that will impact your shop and the environment in a positive way even if you do not live on the West Coast. It is my opinion that these new requirements will improve the pads you are installing on a vehicles. More to come. ■

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Gonzo’s Tool Box

By Scott “Gonzo” Weaver Gonzosae@aol.com

SECOND-HAND INFORMATION When Critical Details Get Lost in Translation

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o you remember when you played the game of “telephone” as a child, and the original information being conveyed was often totally different by the time the last kid commented?

The same thing can happen with a vehicle problem when more than one person is involved in getting the information to the person at the end of the line. And who’s usually at the end of the line? The tech.

Second-hand information can be misleading, even totally wrong. There’s always a chance it might 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 up regarding the condition of a car that was for sale. It was a low-mileage car, and had been sitting in a garage for nearly eight years without much attention. The owner’s father-in-law bought the car new before he passed away. The rest of the family had informed the son-in-law that everything was in tiptop shape. It definitely was clean, dent free, the paint still looked great and there wasn’t a blemish on the interior.

As with any of these “moth-balled” cars, the first thing that was an issue was the battery. When a battery sits for that long, it’s natural for it to become sulfated. So, the owner had it towed to a shop to have the battery replaced.

After the new battery was installed, it took a few cranks for the engine to start. After a few coughs and shudders, the engine purred like new, but the service light was on. (This seemed to be the major concern for both the seller and the buyer.) But, by the time the car arrived at my shop, the engine codes had been cleared from the PCM by the tech.

All I had to go on was the second-hand information that the owner overheard from the tech who had worked on the car.

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

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It’s that “something” that bothered me. A tuneup, maybe, or I’m thinking it might be old gas, but what’s a “something”? It really doesn’t matter at this point as the buyer jumps into the conversation and says, “Do a complete checkup for me, and let me know if it’s worth what they want for it.”

There were numerous small problems to deal with, and a few major issues as well — everything from an ABS light staying on (which neither party mentioned), to a very poorly repaired alternator main positive lead.

With the car in the service bay, you could hear the alternator whine grow louder and louder the longer the car ran. What I did find was that between the alternator and the battery there was a large, homemade connection that was hot enough to fry an egg on. This was causing a rather large voltage drop.

After explaining the ABS problem, the A/C and wiring issues, and all the other problems I found while checking it out, it was clear to me they were not going to purchase the car.

Needless to say, before I could show the owner any of the results, I had a very upset individual at the service counter.

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

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

As I showed him the actual conditions, what he was told regarding the condition of the car came into question. It was only then that he knew he should have had a tech check it out, rather than relying on the second-hand information provided by the family.

Digging through the maze of hearsay information is what a professional technician does every day. And people will always interpret what anyone says into what they “thought” they heard, making our job as a professional tech communicating repair issues even more difficult. ■

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Industry Review AAPEX 2012 Opens And Closes On A High Note 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 performance by the Foothill High School Drum Line of Henderson, Nev. The performance was followed 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 percent 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 accommodate attendees’ schedules. A total of 32 sessions were presented on a range of topics including sales, marketing, branding, warehouse distributor management, industry trends, employee productivity, technology and service readiness.

Attendees gave high marks to sessions and speakers, 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.

GUESS THE CAR! WIN $50! #10

What vehicle MAKE does the picture on the left represent?

Submit your guess with our online contest form by visiting www.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 Navigator Solved by: Shaun McKelvin of McKelvin and Sons Inc. in Camden, AR.

#9

CONGRATULATIONS SHAUN!

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

Industry Review Navy Veteran Finds Business Success With Meineke Car Care Center In May, Navy veteran Tom Perez purchased a Meineke Car Care Center location in Pensacola, Fla., with the help of Boost A Hero, a crowdfunding site to help veterans open franchises. Perez raised $6,740 through Boost A Hero, and Meineke discounted the franchise fee and provided additional financing, making it possible for Perez to take over the Pensacola location.

In his first six months in business, Perez, 31, has hired five veterans, keeping his promise to help other veterans find jobs. He also has increased sales for his location by 60 percent, and he hopes to open a second center. Perez has been nominated for the International Franchise Association’s (IFA) Veteran of the Year award and is a finalist for the U.S. Chamber of Commerce’s Hiring Our Heroes award.

“When I was forced to leave the Navy after 10 years of service due to downsizing, I tried to find a job as a police officer. I had served as master of arms and was a decorated veteran, but I couldn’t find a job,” Perez said. “I looked into opening a franchise and Meineke was clearly a great business opportunity. The skills I learned in the military have been a key part of my success, and I’m looking 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 many tours in other locations. He received four Navy/Marine Corp Achievement Medals, the Defense Meritorious Service Medal, the Joint Service Achievement Medal, the Navy Unit Commendation, Meritorious Unit Commendation, three Good Conduct Medals, the National Defense Medal, the Iraq Campaign Medal, the Global War On Terrorism Service Medal, the Global War On Terrorism Expeditions Medal and the Outstanding Volunteer Service Medal.

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Industry Review NUCAP Industries Announces New Coverage For Drag Reduction Technology (DRT) Brake Hardware System One year since the launch of DRT, NUCAP continues pushing to meet the needs of its customers and further improving the performance and value of their vehicles.

NUCAP marks the one year anniversary of the Drag Reduction 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, some original equipment brake systems began incorporating hardware designs to reduce brake drag. In addition to impacting fuel economy, reducing brake drag has also been shown to reduce brake noise, decrease pad wear and enhance vehicle performance, which is good for the environment and your budget. NUCAP DRT brings this technology to the Aftermarket to provide this benefit to the large population of vehicles currently on the road that were 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.

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Honeywell Friction Materials' Enhanced Online Catalog Offers New VIN Look-Up Feature Honeywell Friction Materials has introduced a new, enhanced online catalog for the Bendix brand, which allows users to input the VIN to find the appropriate part number.

Honeywell Friction Materials improved its user e-catalog experience after conducting qualitative research and securing comprehensive feedback from customers.

Now, users are able to easily access a search function from anywhere on the Bendix website. After entering the VIN into the search, users will be directed to a page with the exact Bendix part recommended for the vehicle, with specifications and a link to a troubleshooting video. Having this comprehensive information available saves time and helps eliminate the need for a phone call with a rep or distributor, according to Honeywell.

These new upgrades come on the heels of several ecatalog enhancements Honeywell Friction Materials made earlier this year. In May, the company put a system in place so that industry standard-formatted files can easily be generated for all of its customers. The company also launched the Bendix catalog app for smartphone users, allowing repair shop technicians and do-it-yourselfers to look up parts information and access images and product specs with the touch of a button.

According to Honeyewell, the e-catalog initiative, a major focus for the company in 2012, is part of the new Bendix website rollout, which has been designed with a simple interface that helps users quickly find what they’re looking for. The new site is set to launch this November.

“We designed the part search function to be an indispensable tool and not just a repository of information,” said Grif Jordan, product marketing manager at Honeywell Friction Materials. “The content is connected to mimic the technician’s workflow. After they identify a part, any additional Honeywell alternatives reflecting either greater value or performance upgrades compatible with their search are listed to provide even greater product selection. Users will also have the appropriate ordering detail, any specific installation notes, links to troubleshooting training videos and even third-party forum discussions on the product collected for them without having to go search additional sites or navigate through exhaustive asset libraries to find the right detail.” ■

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Tech of the Year

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

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im Brant, an automotive technician at Joe’s Tire and Auto Service, St. Joseph, MO, has been named the 2012 Best Tech, sponsored

by WIX Filters.

WIX Filters, a member of the Affinia Group family of brands, in conjunction with Brake & Front End, ImportCar and Underhood Service magazines, named Brant the secondannual WIX Filters Best Tech during the annual Automotive Warehouse Distributors Association (AWDA) Meeting and Conference in Las Vegas on Oct. 29. As part of his award, he and a guest traveled to the Automotive Aftermarket Products Expo (AAPEX) for an all-expenses paid trip to Las Vegas.

“From the diagnosis of electrical problems to evaluating exhaust systems to recommending the best parts — technicians play a major role in enhancing a vehicle’s performance,” said Mike Harvey, brand manager for WIX Filters. “We are thrilled to recognize Kim Brant for the secondannual Best Tech award for his distinguished career built on outstanding customer service as a committed advisor and resource, and for his dedication to learning as vehicles become more sophisticated with a wider range of repairs and maintenance work.”

Brant, an ASE Certified Master Technician and a WIX Expert-Level Certified tech, said he was

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

“With complicated systems that make up automobiles today, it is imperative that technicians provide the highest-quality service to ensure that drivers and passengers are safe on roadways,” said Brant. “I am truly delighted to win this award not only for myself, but for everyone at Joe’s Tire & Auto Service. From our technicians, owners to service writers, we hold the shop to the highest standards by encouraging ongoing education, implementing top-level industry standards and providing excellent customer service, which drives returning customers.”

Tech of the Year Brant, who has been in the automotive and repair service industry for 28 years, was a runner up in the 2011 Best Tech program last year. He’s worked at Joe’s Tire and Auto (www.stjoeautoservice.com) for about four years, and before that served as a technician in a few local dealerships and tire stores.

Besides his exceptional customer service, Brant has been active in his community’s youth organizations and local technical school. He also is credited for his penchant to go the extra mile to gain a new customer for Joe’s Tire and Auto Service, an independent repair shop that has been servicing the St. Joseph area since 1984.

“My biggest enjoyment from the auto industry is the challenge of determining the vehicle failure and taking that process clear through to returning the vehicle to the customer, properly repaired,” he said.

Brant, whose own “fleet” of vehicles includes his daily drive, a 1999 Dodge Grand Caravan, also owns a 1988 GMC 1500 4x4 and a 1966 Dodge Dart GT Convertible. His love of vehicles developed at an early age

COMMUNITY INVOLVEMENT In addition to his service as an automotive technician, Brant also was recognized for his community service that includes: • Raising money for Habitat for Humanity; • Raising money for the Special Olympics; and • Participating in Neighborhood Beautification programs and recycling efforts.

through his father’s business.

“My father owned a Mobil service station from my infancy to my teenage years,” Brant said.

“Without his involvement in the automotive world, I’m sure that I would not be involved myself.”

One of the most unique jobs Brant had seen as a technician had to be the servicing of an A/C system on a local Life Flight helicopter that had been grounded.

Since the law requires the A/C system to be in working order for the helicopter to be used for medical purposes, Brant was asked by his shop owner if he could fix the helicopter’s A/C system since the company that previously serviced the craft was

no longer in business.

Although he had never repaired a vehicle that is designed to leave the ground, Brant hit the Internet to research the helicopter’s HVAC system, grabbed his tools and headed out to Rosecrans Memorial Airport, where he was greeted by the Life Flight air staff.

After servicing the A/C system successfully, Brant said he was confident he would be contacted to service the system if it ever needs it in the future.

Brant said he was happy to be of assistance in the Life Flight’s return to the skies, and that today’s shop’s can find business “outside the box.”

“I’ve worked on a lot of unique vehicles — from Ferraris to Lamborghinis to Prowlers — but not many techs in this business can say they have worked on a helicopter.”

And not just any helicopter, but a Life Flight helicopter. ■

RUNNERS-UP WIX Filters and Babcox Media also named two 2012 Best Tech finalists: Travis Luscomb from Larson’s Service, Inc. in Peabody, MA, and Kevin Dietz from BTS Tire and Service in Providence, RI. Circle #14 for Reader Service

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Brought to you by:

Product Showcase

AutoCareProNews.com

With an estimated 60% of vehicles on the road in need of an alignment, Hunter Engineering Company developed 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 measurements and produces printed results in under a minute. Service writers can then use the easy-to-understand, color-coded printouts to alert customers of misalignment issues and generate more repair orders for alignment service.

Circle #90 for information

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90 NAPA is the handy place to get gifts for a handyman this season.

Starting November 18th, stop into a participating NAPA AUTO PARTS Store and pick up a GearWrench 7-piece Ratcheting Wrench Set — in standard or metric — for just $29.99. Or, a Crescent 5-piece Locking Plier Set, just $26.99. Promotion ends 12/31/12, while supplies last. www.NAPAOnline.com

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Circle #91 for information

Federal-Mogul has added 36 parts, including 14 new control arms, to its line of MOOG Steering and Suspension components. According to Federal-Mogul, as the automotive service market’s “Problem Solver,” the MOOG brand offers innovative product designs that help ensure enhanced performance and durability and easier installation. The latest expansion of the MOOG line includes 14 new control arms for a wide range of foreign nameplate and domestic applications.

Circle #92 for information

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Tenneco’s Monroe Brakes brand now offers a portfolio of advanced braking solutions tailored to the needs of significantly more consumers. New Monroe ProSolution brake pads – positioned as a premium technology available at a mid-range price – complement the company’s popular Total Solution offering of Monroe Ceramics and Monroe Dynamics ultra-premium pads in a program designed to help distributors, jobbers and service providers increase their shares of the brake repair market.

Circle #93 for information

94 Using the Bartec Tech400SD TPMS tool, technicians can program new TPMS sensor IDs on GM and Ford vehicles through the OBDII connection. With the Tech400SD, 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 the Tech400SD, the relearn process is the same on a Toyota Camry as it is on a Chevrolet Impala. That means learning only a single method of repair on a domestic and imported vehicle.

Circle #94 for information

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Brake Job

TOYOTA

Toyota Brake Tips HERE ARE THE TOP TOYOTA BRAKE TIPS THAT CAN SAVE YOU FROM A COMEBACK OR LOST PRODUCTIVITY.

SIX, SIX OR FIVE: ORDERING TACOMA BRAKE PARTS PREPARATION 1995-2004 TACOMA When ordering parts for a V6 model, make sure you tell your parts supplier if you are working on a Pre-Runner or 4WD model. The calipers may look the same, but there are differences in the pads and rotors. Some electronic catalogs have trouble telling the difference.

REPLACE THE BRAKE HOSE IF THE CALIPER HAS OVER HEATED If you are replacing a caliper that has locked up and created a great deal of heat, you should also replace the brake hose. This is a good practice anytime, but particularly important with the Toyota line as there have been some instances of the hose failing at the caliper fitting after being subjected to the extreme heat.

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RUNOUT REMEDY All Models You can lower the runout by changing the position of the rotor on the hub flange. With this technique, you can minimize the amount of material removed from the rotor during onthe-car machining. This can make a more thermally stable rotor that absorbs heat evenly and reduces pulsation comebacks.

REAR AXLE LOAD VALVE LOW PEDAL 1995-2004 TACOMA One problem area is the load-compensating valve that attaches to the rear axle. The

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Brake Job

TOYOTA

ALL HYBRIDS: DEACTIVATING HYBRID SYSTEM If you are replacing calipers or other hydraulic components on a Prius or other Toyota Hybrid, you will have to deactivate the system with a scan tool. Most

mechanical linkage and the valve causes problems on some trucks by leaking and increasing braking distances. The main culprit is rust and corrosion. The valve is designed to change brake hydraulic pressure in the rear brakes as the load changes the relationship between the body and axle. Some technicians

have reported the spare tire can come in contact with the linkage if the carrier mounting points fail due to corrosion. When replacing the unit, it is critical to adjust the linkage. Make sure there is 78 mm of distance between the center of the bolt on the axle shackle and the center of the bolt on the arm that connects the linkage to the valve for 2WD trucks and 120mm for 4WD trucks.

scan tools will walk you through the process that involves removing the two ABS pump relays and pumping the pedal in a sequence to depressurize the system. The system can also be deactivated by waiting for two minutes after turning the power switch OFF, stopping the brake pedal operation and closing the driver door before removing the two relays for the ABS system.

Also, it is a good practice when working on vehicles with advanced ABS and Stability Control systems to remove the keys from the vehicle and place in a different room, like at the front counter. Also, it may take at least five minutes for the car to go into a sleep mode.

PRE-2005 TUNDRA OFFTHE-SHELF BRAKE UPGRADE It is possible to upgrade the brake system on some pre-2005 Tundra trucks using off-the-shelf parts. An upgrade was engineered and information was proCircle #20 for Reader Service

Brake Job vided through a service advisory, as production changes added a larger caliper system in front and disc brakes in the rear to substantially improve braking performance, while reducing the incidence of pulsation complaints. This upgrade became the standard brake system on late 2005 truck models.

While some of these trucks were updated under warranty, others have been transferred to new owners and the problems show up again as these new owners subject them to heavier-duty use. That’s where this update becomes an opportunity for independent repair shops to educate and earn the trust of owners of these vehicles.

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Brake Job

HYBRIDS: BRAKE PAD CONSIDERATIONS The Prius has unique requirements for the brake system. On 2001-2004 models, the hydraulic brakes were not used until the vehicle was below 7 mph or if the vehicle had to make a hard stop. Later models use a more sophisticated system that may engage the brakes at higher speeds.

The majority of the time, the pads never reached conventional operating temperatures and corrosion could occur between the backing plate and friction material due to the fact that the pads never dried out. On some vehicles, the corrosion between the friction material and backing plate would cause a complete separation. Always use a highquality pad for hybrid applications to avoid problems. It is not a question of better performance.

It is a question of quality and engineering.

Since it is impossible to perform a conventional break-in/bedding procedure on the test drive, make sure the manufacturer promises excellent performance right out of the box. Also, applying a nondirection finish with a ball hone Circle #22 for Reader Service

TOYOTA

will help the new pads evenly deposit a layer of friction material to the new rotor.

HYBRID: PRIUS BRAKE NOISE FROM PEDAL

Some 2004-07 Prius Hybrids may produce an annoying squeaking sound when the brake pedal is applied or released.

Toyota says the noise is most audible when the key is in the Ready mode with the vehicle not moving. A defective brake actuator assembly is the likely culprit.

Before condemning the actuator, however, try bleeding the brake system. If the noise goes away, you’re done with the fix. If the noise remains after getting out that last belch of air, replace the brake actuator with an upgraded unit, Part No. 44500-47090. â–

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December 2012 | BrakeandFrontEnd.com

2002-2006 MINI COOPER

Bushings: 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 camber and toe will change when the bushings go soft.

BMW recommends replacing the bushings in pairs.

Rear Camber: The rear camber is not adjustable. If the rear camber needs to be adjusted, it requires replacement of the lower control link with an adjustable part.

Rear Toe: Rear toe is adjusted by an eccentric bolt and plate that secures the lower transverse link to the trailing arm.

The rear toe and camber 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.

SPONSORED BY

TPMS: The first-generation Mini has two TPMS systems 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 systems, 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).

Front Camber or Caster: 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 camber by ±2.00º and caster by ±0.75º.

Alignment Spec

Steering Angle Sensor (SAS): On Minis without Electronic Stability Control (ESC or DSC), SAS is not installed. Reprogramming the sensor on ESC Minis requires an enhanced scan tool that can communicate with the ABS and BCM modules.

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O2 Sensor

Oxygen Sensor Internal View

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n oxygen sensor is made of Zirconium Oxide (ZrO2), a chemical compound used to form the sensor’s thermal-driven electrochemical fuel cell. The Greek letter Lambda is used to describe the voltage range of the sensor when it compares the quantity of oxygen in the exhaust relative to oxygen in the atmosphere.

Two Platinum (Pt) electrodes are placed on the ZrO2 to provide a connection for output voltage to a control module.

A Planar Air Fuel Sensor is a combination of a standard Zirconium Oxide Oxygen sensor and a Pump Cell to maintain a constant sensing of a stoichiometric air fuel ratio through the extreme rich and lean conditions. The pump cell is a diffusion gap in the Zirconium Oxide of the sensor that is connected to a control circuit.

The pump cell controls the oxygen concentration of the sensor by adding or subtracting oxygen to the diffusion gap.

Input to the electronic circuit modifies the oxygen concentration by changing the polarity of the current flow in the pump cell. The changing polarity of the input and trim current flow causes the control circuit to send a rich or lean signal to the engine control module.

How long should an oxygen sensor last?

An oxygen sensor should outlast the vehicle emissions warranty. With proper powertrain maintenance, it is possible for

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the sensor to last the life of the vehicle, which could be in excess of 250,000 miles.

When does an oxygen sensor need to be replaced?

The service engine soon light will come on and a diagnostic trouble code(s) will be stored.

There may be multiple codes stored for a sensor. A fuel delivery malfunction can be the reason for an oxygen sensor to fail.

Do oxygen sensors degrade over a period of time?

Simple answer: Yes. What causes an oxygen sensor to degrade? When silicon was an ingredient in RTV and coolant, the silicon could cause the sensor to rapidly degrade. It was referred to as silicon poisoning.

Sulfur can cause the degradation of an Oxygen sensor and the concentration of the Sulfur in the gasoline will determine the rate at which the sensor will degrade.

Motor oil contains phosphorous, and zinc also cause the degradation of the sensor when excessive oil vapor is introduced through crankcase ventilation.

What can cause an oxygen sensor to fail?

The most vulnerable part is the wiring and connector.

Next is the heater. Its function is to bring the sensor to operating temperature during cold starts and engine warm up. It can be damaged by thermal shock.

Does overall engine maintenance affect the life of an oxygen sensor?

Simple answer: Yes. An important maintenance item is the oil change. It contributes to the life of an oxygen sensor.

Positive Crankcase Ventilation (PCV) can contribute the degradation of the oxygen sensor.

Vapors from contaminated oil in the crankcase can shorten the life of an oxygen sensor. â–

Circle #27 for Reader Service

Tires

2012

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

FORD TSB Number: 12-6-2 Vehicles: 2009-2011 Ford Edge and Mercury MKX Condition: Corrosion and on the lip of 22-inch rims and whiskers/vents on the tire’s bead seat may cause the TPMS to illuminate.

Solution: Disassemble the rim and tire and clean the rim and tire bead seats with a maroon Scotch-Brite pad.

GM TSB Number: 00-00-90-002K Vehicles: All GM Vehicles with direct TPMS systems.

Subject: Adjusting tires under warranty.

This TSB is an advisory stating that adjustment of tire pressures is not a warranty procedure. It also defines a cold tire as one setting for at least three hours. It also advises against the use of non-GM tire sealants.

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

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December 2012 | BrakeandFrontEnd.com

This TSB is an update of a TSB issued in 2010 on the use of nitrogen in tires. This TSB does not endorse nor advise against the use of nitrogen in tires. But, the TSB does make some caveats. It does describe the “theoretical benefits” of nitrogen, but it also says that it is difficult to obtain nitrogen in a purified state that could deliver the benefits in the field. If you read between the lines, this TSB says: “GM vehicles are designed to work with atmospheric air, but nitrogen can benefit the drive if the purity of the nitrogen is kept.

INFINITI TSB Number: 12-29 Vehicles: All Infiniti models with TPMS. Subject: Damage to TPMS sensors Infiniti pulls no punches here! The luxury brand of Nissan tackles two of the leading causes of

Circle #29 for Reader Service

Tires sensor damage.

Infiniti tells technicians that deep well, long reach air chucks can break and bend stems. It even advises against the use locking chucks. The TSB recommends the use of shallow chucks without extensions.

While some OEMs have stated that some sealants are compatible with sensors, Infinity states that some sealants and propellants can crack the housing of sensor. The pictures in the TSB are hard to dispute.

TSB Number: 12-046A Models: 2013 JX35 Subject: TPMS registration procedure.

This TSB is of little consequence to technicians who use an aftermarket scan tool to register IDs with the TPMS module. The procedures discussed concern new hardware and software for the CONSULT III scan tool.

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

Jaguar issued this TSB to advise technicians to be careful with valve stems during inflation or valve cap removal. The TSB advises strongly against metal valve stem caps that can cause galvanic corrosion. It also advises that if the customer has used non-approved valve caps, that all four or five sensors should be replaced.

LEXUS TSB Number: SB-0042-12 SB-0055-12 SB-0056-12 SB-0073-12 SB-0082-12 SB-0083-12 SB-0085-12 SB-0100-12 Subject: Sensor activation on 2013 models.

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

MAZDA TSB Number: 02003-12 SUBJECT: Activation of sensors.

Model: 2013 CX-5

Tires This TSB describes how the TPMS system operates and how to service the system.

Instructs technicians how to relearn sensor positions and possible symptoms for a problem.

MITSUBISHI TSB Number: 12-31-001 Models: All Models with Direct TPMS from 20042012 SUBJECT: TPMS General Service Procedures This 11-page TSB outlines how to service and diagnosis Mitsubishi vehicles equipped with TPMS. This is one of the most complete TSBs ever published. This is a must read that should be printed out.

includes a chart that plots temperature and pressure. This TSB will help you determine the correct tire pressure in all seasons. SB0001-12 is another “must print” TSB for technicians.

VW TSB Number: 4412-02 Models: 2012-2013 CC This TSB informs technicians that some CC models may experience a loss of signal from a single or multiple TPMS sensors. The only solution is to replace all four sensors with updated sensors from HUF. ■

NISSAN TSB Number: 10114B Vehicles: All Infiniti Models With TPMS Subject: Damage to TPMS sensors Nissan pulls no punches here! Nissan tackles two of the leading causes of sensor damage.

The OEM tells technicians that deep well, long reach air chucks can break and bend stems. It even advises against the use locking chucks. The TSB recommends the use of shallow chucks without extensions.

While some OEMs have stated that some sealants are compatible with sensors, Nissan states that some sealants and propellants can crack the housing of sensor.

SCION TSB Number: SB0001-12 Subject: Inflation pressure temperature compensation.

Scion released this TSB to inform technicians how ambient temperatures can influence tire pressure. The release Circle #31 for Reader Service

Tech Tips

FORD / BMW / SUBARU / HONDA This month is sponsored by:

FORD: F250 & F350 Memory Steer Solution The chassis group at Affinia Global Brake and Chassis – the makers of Raybestos chassis parts – have one thing to say when it comes to memory steer… FORGET ABOUT IT! Memory steer may occur when replacing upper and lower ball joints on a Ford F250, 350 or 450 with a Dana 60 axle.

There are three major factors that can lead to memory steer: • Not removing and cleaning the camber/caster sleeve so it can move freely during the installation; • Improper use of the ball joint press; and • Not using the torque wrench properly or following the proper 1-2-3 torque sequence.

Fortunately, memory steer can be easily corrected. The repair procedure is as follows, using P/N 500-1048 (Upper Ball Joint) and P/N 500-1181 (Lower Ball Joint): 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, including recessed area into which the ball joint flange fits. (Figure 1) 4. Place the new ball joint in a vise to articulate stud and rotate. Prelubricate the joints at this time.

Install upper and lower ball joints into the steering knuckle using a Figure 1 ball joint press and adaptors making sure the adapter fits the outer flange area. (Figure 2) 5. Before installing the knuckle assembly in yoke, index camber/caster adjustment sleeve before removing and cleaning. It is important

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December 2012 | BrakeandFrontEnd.com

Figure 2

that the sleeve moves freely in the axle yoke.

(Figure 3) 6. Install knuckle assembly into the yoke.

(Follow the torque sequence noted below to ensure a proper instalFigure 3 lation.)

Torque the lower ball joint. Make sure caster/camber adjustment sleeve moves freely. Torque the upper ball joint. 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 correcting memory steer can be found on the Raybestos brand channel of YouTube: http://www.youtube.com/watch?v=SKChabX19 YA. For more information on additional chassis solutions or other Raybestos brand brake or chassis parts, visit www.raybestos.com or call 800-3230354.

Courtesy of Affinia Global Brake and Chassis – the makers of Raybestos.

Circle #33 for Reader Service

Tech Tips

BMW / HONDA / SUBARU

BMW Electric Power Steering Is Not Working Properly The customer may complain that the electric power steering is not working properly.

Vehicle Application: 2003 BMW Z4 2.5L and 3.0L, and 2004 Z4 2.5L

Customer Concern: The electric power steering is not working properly.

Potential Causes: Defective electric motor power steering (emps), blown fuse or damaged wiring harness.

Tests/Procedures: 1. The electric power steering system on this vehicle is a one-piece unit that has the control module and the power steering assist motor.

2. Check for proper power and grounds at the module.

Fuse 22 and fuse 64 both feed the assembly. They provide battery voltage on the red

wire and the green/white wire.

3. The brown wire should be chassis ground.

4. Other wires are for communication and a signal from the steering angle sensor.

These values can be checked in the datastream of a scan tool, but should not be a problem if there are no related codes stored for them.

Cause: The power steering assembly should always have a centering clip installed on the shaft whenever it’s removed from the vehicle. Once installed, the clip can be removed. A new module should have the clip installed; if not, return the module and get another one. Never install a used one because they will not be centered and clipped properly. New modules also require coding and steering angle initialization after installation.

Courtesy of Identifix.

REAR ROTOR RUBBING ON BACKING PLATE AFTER INSTALLATION On some Subaru, Honda and other vehicles utilizing a “Drum-in-Hat” type parking brake system operated in a corrosive environment (road de-icers, salt, etc), the new rear brake rotor may rub against the backing plate. This condition may be caused by corrosion between the backing plate and knuckle assembly that has “jacked” the backing plate away from the knuckle such that it makes contact with the brake rotor. While some may machine/grind the inboard-most edge of the parking brake drum, the correct course of action is to disassemble the parking brake, remove backing plate from knuckle, thoroughly clean all components (replace parts as necessary) and reassemble. ■ Courtesy of Centric Parts www.centricparts.com Circle #34 for Reader Service

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Advertising Representatives The Tech Group Bobbie Adams badams@babcox.com 330-670-1234, ext. 238 Dean Martin dmartin@babcox.com 330-670-1234, ext. 225 Sean Donohue sdonohue@babcox.com 330-670-1234, ext. 206 Glenn Warner gwarner@babcox.com 330-670-1234, ext. 212 John Zick jzick@babcox.com 949-756-8835 List Sales Manager Don Hemming dhemming@babcox.com 330-670-1234, ext. 286 Classified Sales Tom Staab tstaab@babcox.com 330-670-1234, ext. 224

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Brake Lights

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

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