Chevrolet Sonic Repair Manual: Brake Drum Refinishing

Chevrolet Sonic Repair Manual / Chassis / Brakes / Drum Brakes / Brake Drum Refinishing

Special Tools

CH-41013 Rotor Resurfacing Kit
CH-42450-A Wheel Hub Resurfacing Kit

For equivalent regional tools, refer to Special Tools.

Warning:

Refer to Brake Dust Warning.

The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions:

Brake system noise (squeal, growl, groan)
Uneven and/or premature brake lining wear
Superficial or cosmetic corrosion/rust of the brake drum surface
Scoring of the brake drum surface (less than the maximum allowable specification)

Brake drums should only be refinished if the following conditions exist:

Excessive corrosion/rust and/or pitting
Cracks and/or heat spots
Excessive blueing discoloration
Scoring of the brake drum surface (in excess of the maximum allowable specification)
Radial runout in excess of the maximum allowable specification

Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification:

With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. Refer to Brake Drum Diameter Measurement.
Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake Drum Surface and Wear Inspection.

If the brake drums can be refinished, proceed with the rotor refinishing procedure.

If necessary, use the CH-41013 rotor resurfacing kit in order to thoroughly clean any corrosion/rust from the brake drum flange.

Mount the brake drum to the brake lathe according to the lathe manufacturer instructions.

Ensure that any vibration dampening attachments are securely in place.

With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface.

Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe.

If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe.

Following the brake lathe manufacturer instructions, refinish the brake drum.

After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter Measurement.

If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced.

After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish:

Follow the brake lathe manufacturer's recommended speed setting for applying non-directional finish.
Using the moderate pressure, apply the non-directional finish:

If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper.
If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper.

After applying a non-directional finish, clean the friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner and wipe the friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles.

Remove the brake drum from the brake lathe.

If necessary, use the CH-42450-A wheel hub resurfacing kit in order to thoroughly clean any corrosion from the wheel bearing flange.

Brake Drum Diameter Measurement

Warning: Refer to Brake Dust Warning. Remove brake drum. Refer to Brake Drum Replacement Clean the brake shoe lining contact surface of the brake drum (2) with denatured ...

Brake Drum Replacement (J93, J94)

Special Tools CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools. Removal Procedure Warning: Refer t ...

Other materials:

Shoulder Belt Replacement - Rear (Sedan)
Shoulder Belt Replacement - Rear Callout Component Name Preliminary Procedure Remove the rear window panel trim. Refer to Rear Window Panel Trim Replacement. 1 Rear Seat Shoulder Belt Anchor Plat ...

Steering Column in Lock Position Caution
Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The ste ...

Torque Converter Housing Cleaning and Inspection
Torque Converter Housing Cleaning and Inspection Callout Component Name Caution: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission compone ...

0.0097