GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Astro - 2WD 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Rotor Refinishing

Tools Required

    • J 39144 Composite Rotor Mounting Adapter
    • J 41013 Rotor Resurfacing Kit
    • J 42450-A Wheel Hub Resurfacing Kit
    • J 39544-KIT Complete Torque Socket Set (10 Pieces)

Important: Do NOT refinish the brake rotors in order to correct any of the following complaints:

   • Brake noise (growl/squeal)
   • Premature brake lining wear
   • Cosmetic or superficial corrosion of the rotor braking surface
   • Rotor discoloration
Refinish the brake rotors ONLY when one or more of the following conditions exist:
   • Severe scoring of the rotor braking surface (groove depth in excess of 1.5 mm (0.060 in)
   • Brake pulsation caused by the following:
      - Brake rotor thickness variation in excess of 0.025 mm (0.001 in)
      - Corrosion or pitting of the rotor braking surface that is deeper than the rotor braking surface

The following brake lathes are approved and achieve satisfactory results.

    • Accu Turn® (off-vehicle)
    • Pro-Cut® (on-vehicle)

    Notice: Do not allow the brake components to hang from the flexible brake hoses. Damage to the brake hoses could result.

  1. Remove and support the brake caliper.
  2. Make a mark on the brake rotor in order to identify the relationship to the hub.

    3. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation.

  3. Remove the brake rotor.
  4. Use the J 42450-A in order to clean the wheel bearing/hub.
  5. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor.
  6. Use the J 41013 (or equivalent) in order to thoroughly clean the rust from the rotor/hub flange and from the rotor/wheel mating surfaces.
  7. Install the brake rotor.
    8. • If you use the Accu Turn® (off-vehicle) brake lathe, install the brake rotor to the brake lathe. If you are machining a composite rotor, use the J 39144 . Refer to the brake lathe manufacturer's operating instructions.
    • If you use the Pro-Cut® (on-vehicle) brake lathe, install the brake rotor to the vehicle. Align the brake rotor to the hub using the marks made during the removal procedure.
  8. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions.

    9. Important: Failure to obtain the best possible rotor finish may cause the vehicle to stop with difficulty.

  9. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher (if available) in order to create a non-directional braking surface.
  10. Clean the braking surfaces with denatured alcohol or with a suitable brake cleaner.
  11. If you use the Accu Turn® (off-vehicle) brake lathe, remove the brake rotor from the brake lathe and install the brake rotor to the vehicle. Align the brake rotor to the hub using the marks made during the removal procedure.
  12. Install the brake caliper.

    13. Notice: Improperly tightened wheel bolts or nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel bolts or nuts to the proper torque specification.

  13. Use the applicable torque socket from the J 39544-KIT or a torque wrench in order to install the wheel to the correct specification.