Service Bulletin

Mazda North American Operations
Irvine, CA 92618-2922

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© 201 3 Mazda Motor of America , Inc.

Subject:

Bulletin No:

04-004/13

Last Issued:

11/11/2013

BRAKE NOISE, JUDDER AND DRAGGING DIAGNOSIS AND SERVICING

BULLETIN NOTE
• This bulletin supersedes the previous bulletin 04-007/11 issued 10/ 17/11 and 04-006/09 issued 06/02/09 .
The APPLICABLE MODEL(S)NINS have been revised.
• Changes are noted below in Red beside the change bar.

APPLICABLE MODEL(S)NINS

2011-2014 Mazda2

2003-2014 Mazda6

2007-2014 CX-9

2004-2014 Mazda3

201 3-2014 CX-5

2006-2014 MX-5

2006-2014 Mazda5

2007-2012 CX-7

2004-2011 RX-8

DESCRIPTION
Some vehicles exhibit brake related concerns such as brake noise, brake judder or brake dragging . If you
encounter a customer complaint for any one of these symptoms, refer to the following information to understand
why symptoms may occur, and to better assist the customer in resolving their specific brake concern.

REPAIR PROCEDURE
BRAKE NOISE
There are various types of brake noise and many different conditions that can cause noise. Frictional co-efficient between brake pads and rotors varies depending on pad material , temperature, humidity, braking force,
etc. During braking , the brake pads are pressed with great force against the brake rotor. This generates friction
to bring the vehicle to a stop.
• If the brake pads are of a soft compound , a larger amount of brake dust will appear on the wheels and the
pads will wear more rapidly, but there will be less chance of brake noise .
• If the brake pads are of a hard compound (as used in high-performance applications) , less brake dust will
appear, the pads will last longer, and braking performance will be improved . However, the drawback is that
brake noise can occur more easily than with softer compounds.
Finding a balanced compound with the qualities of both hard and soft compounds is difficult.
If you encounter a customer complaint for brake noise, first determine which wheel the noise is located at and
repair the cause of the noise. After the repair is complete, explain to the customer that it is very difficult to completely eliminate brake noise from any vehicle, and that the noise could return with increased time and mileage.
Groan Or Squeak Noise:
• If the noise is a groan or squeak while the brakes are applied, refinish the brake pads (providing they have
adequate thickness) using sandpaper (grit #80) or replace the brake pads with new parts.
Page 1 of 3
CONSUMER NOTICE : The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by "do-it-yourselfers." Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern . To determine if the information applies,
customers should contact their nearest authorized Mazda dealership . Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved . No part of this bulletin may be reproduced in any form or by any means,
electroni c or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

Last Issued: 11/11/2013

Bulletin No: 04-004/1 3
© 201 3 Mazda Motor of Ameri ca , Inc.

Brake Dragging Noise:
• If the noise is due to brake dragging , ~heck the caliper and sl,iders to ensure they are not seized,. Rebuil_d or
replace the caliper and sliders as necessary.
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Rattle Or Clunk Noise:
• If? rattle or clunk noise is pre?ent, replace the brake pad shims/mounting hardware or t'E;!place the pads afte·r
inspecting the fitment df all parts and determining the cause of the excessi.ve clearance.
When performing a repair requiring refinishing or replacement of the brake pads, lightly sand (use grit #80) the
brake rotors to remove old pad material. In most cases , brake rotor replacement is not necessary·to remedy a
brake noise condition .
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NOTE:

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Apply locally sourced CRC Disc Brake Quiet (P/N 05016) to the pad backing plates before each of
the above repairs .
Do not use grinding wheels or ai r power tool s.
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BRAKE JUDDER . : ·:

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Brake judder (or warping) is caused by uneven thickn-ess (runout) of th~ brake rotor. Dul-ing braking, tlie clearance between the pads and rotor beeomes wider and narrower. This causes, force onto the pads and may create a vibration . Vibration is transferred through the brake .hydraulic system and/or suspension aqd can be felt by
the customer through the brake pedal , vehicle floor and/or steiering wlieel. Even micron-size un~venness· may
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cause brake judder. Brake judder is more noticeable when slowin·g from "a higher' speed .
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In most cases when brake judder is diagnosed, the rotqrs can be machined u_sing an on-car lathe anq the pads
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can be refinished using sandpaper to restore braking-performance.
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NOTE: DO NOT use an off-car lathe for warranty repair.
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It is not necessary to replace the rotors and pads unless: .
• Excessive unevenness (runout) of the rotors is present that G.an ot be remedi.ed by resurfacing without
exceeding the minimum thickness of the rotor.
• Excessive heat damage to the rotor (may include heatpac ~ing) ., ; _
• Excessive heat damage to the pads.
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Wher;1 you ~neounter a customer complaint for brake judder, discuss the CU$tO qiler's driving and vehicle storage
habits. Identify which wh~el . is causing tt;Je judder and v j s ~ ally inspect th ~Jotors a_r;t? pads to identify the cause .

NOTE:

Refe~ ·to MS3 online -service information or Workshop Manual section 04-50 for lateral runo!Jt, minimum rotor, and minimum pad thickness specifications for the subject vehicie .

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Rust:
• If rust on the rotors and/or brake pads is identified as the cause of the ur1evenness, measure the lateral
· runout and mach.ine th.e rotors using an on-car lathe;.refinish the pads with sandpaper (grit #80) .
If machining the- rotors does not correct the brake ]udder, replace the rotors .

Excessive Heat Damage:
If the rotors ti:~ive excessive heat damage or cracking , replace them . .
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Signs' of rotor heat damage include blue spots or hard spots.

• If the rotors do not have excessive heat damage or cracking , measure the lateral runout and machine the
rotors using an on-car lathe. If machining the rotors does not correct the brake judder, replace the rotors.
• If the brake pads are heat damaged, replace them.

NOTE:

Signs of brake pad heat damage include shiny surfaces or backing plate paint flaking .

• If the brake pads are not heat damaged , refinish them with sandpaper (grit #80) .
Page 2 of 3

Bulletin No: 04-004/13

Last Issued: 11/11/2013

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© 2013 Mazda Motor of America , Inc.

Brake Pad Dragging:

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A dragging brake pad ~ill cause excessive he.at and may warp the rotors. This may result in brake jt,Jdder. Per·
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form the inspection and repair for "Excessive Heat Damage".
NOTE: . During rotor replacement , en~ure the hub is free fromanyfor~ign substan~es that'm ay preyerit ttl~ :
rotor from fitting
flush
against
'.the
hub.
A r9tor th_a.t'does not fit flus_
h against
.the hub may experience a
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reoccurrence of brake judaefr. · ···
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BRAKE: DRAGGING
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This procedure will assist in finding the cause and appropriate repair for the brake dragging . '

Inspection:
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1. Safely raise the vehicle on a hoist.

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