PROCUTUSA.COM Rotor Matching Seminar 2010 presented by Pro-Cut International

GOAL A 1 st rate brake job. SLIDE 2 PROCUTUSA.COM Early disc brake vehicles had heavier braking systems and used softer compound asbestos content brake pads… Rotor Matching Seminar 2010 …this combination caused less lateral run-out induced thickness variation as the friction material would wear before the rotor. The vehicles and drivers were also less sensitive to vibrations.

SLIDE 3 PROCUTUSA.COM Rotor Matching Seminar 2010 As vehicles have become lighter and more sophisticated, they have also become extremely sensitive to even slight amounts of run-out induced thickness variation!

SLIDE 4 PROCUTUSA.COM Consider this: When bench lathes were originally designed, most cars had drum brakes. The ability to machine rotors was an added feature to the bench lathe! The bench lathe was also designed to machine flywheels since most vehicles had manual transmissions Modern vehicles are lighter, and handle and stop better than cars from the 60s. They require modern solutions for precision repairs. …and brake service equipment has changed too! New Technology Pro-Cut PFM 9.2DRO Rotor Matching System Rotor Matching Seminar 2010 Old technology bench lathe

SLIDE 5 PROCUTUSA.COM 1Brake pulsation: cause and effect 2Brake rotor repair alternatives 3Auto Manufacturer positions on brake rotor repair methods 4Hub mount on-car machining overview 5Related repair issues 6PFM 9.2DRO On-Car Brake Lathe presentation MODERN BRAKE ROTOR REPAIR Rotor Matching Seminar 2010

SLIDE 6 PROCUTUSA.COM Rotor Matching Seminar Prevalence of Lateral Run-Out (LRO) caused by stacked tolerances of components 2LRO leads to uneven wear 3Uneven wear leads to thickness variation (TV) 4TV is felt as brake “judder” or pulsation CONCLUSION: LRO is the root cause of most brake pedal pulsation. BRAKE PULSATION: Cause & Effect

SLIDE 7 PROCUTUSA.COM PROBLEM: Lateral run-out EFFECT: On every rotation, the high spot of the rotor impacts the brake pad causing thickness variation. Lateral run-out is the root cause of pedal pulsation. Years ago, LRO specifications were in the ” range. Today’s specs have become much smaller, in the range of ”. Selecting the correct method of repair requires considering many variables. Brake Pulsation Primary Cause Rotor Matching Seminar 2010

SLIDE 8 PROCUTUSA.COM Rotor Matching Seminar New rotor replacement with tedious “phase” matching required to confirm LRO is within specification. 2Shims with new or machined rotor — also a tedious lateral run-out correction process and not approved by most OEMs. 3Bench (off-car) machining again with tedious “phase” matching or shims. 4On-car match-machining with a computerized LRO compensating on-car lathe. BRAKE ROTOR REPAIR ALTERNATIVES

SLIDE 9 PROCUTUSA.COM Rotor Matching Seminar Integrity of all components that contribute to stacked tolerances must be confirmed. 2Hub face, inside hat of rotor, and outer rotor surface must be clean of rust and debris in order to eliminate run-out. 3Measurements of rotor thickness and initial LRO are required to determine correct repair method. CONSTANTS FOR ALL BRAKE REPAIR METHODS

SLIDE 10 PROCUTUSA.COM Rotor Matching Seminar 2010 POSITIVE No thickness variation Usually good surface finish NEGATIVE Little control of total LRO (beyond indexing) National average for parts wait-time is 45 minutes! Complicated procedure on some vehicles (with trapped rotors) Part Cost “double-edged sword” OE rotors can be expensive but quality is best for vehicle Aftermarket rotors can be cheap but quality is often suspect PROS AND CONS OF ROTOR REPLACEMENT

SLIDE 11 PROCUTUSA.COM Rotor Matching Seminar 2010 POSITIVE Approved only by GM Addresses LRO within 0.002” (but can’t guarantee less) NEGATIVE Time-consuming and complicated Safety-fretting issue; adding components Limited coverage; multiple SKUs Only approved by 1 OEM! Not an option for trapped (captured) rotors PROS AND CONS OF SHIMS

SLIDE 12 PROCUTUSA.COM Rotor Matching Seminar 2010 POSITIVE No thickness variation Common procedure/technician familiarity NEGATIVE Matches to bench lathe arbor instead of vehicle’s hub Complicated or impossible procedure on some vehicle’s (those with trapped/captured rotors) Time consuming and complicated to measure and correct run-out PROS AND CONS OF BENCH MACHINING

SLIDE 13 PROCUTUSA.COM Rotor Matching Seminar 2010 POSITIVE No thickness variation No LRO — the rotor is precisely “matched” to the hub Same procedure on all vehicles — trapped or knock off Fast, efficient, and easy to learn Consistent results Change creates new service and revenue opportunity Negative Can’t put material back on rotors Change requires effort PROS AND CONS OF PRO-CUT ON-CAR ROTOR MATCHING

SLIDE 14 PROCUTUSA.COM Rotor Matching Seminar 2010 PFM 9.2 DRO Demonstration Pro-Cut PFM 9.2DRO

SLIDE 15 PROCUTUSA.COM Rotor Matching Seminar 2010 Historical Snapshot

SLIDE 16 PROCUTUSA.COM Rotor Matching Seminar 2010 CHRYSLER Replace — OK only if it can’t be machined Shims: NO Bench: NO On-Car: REQUIRED (Warranty Bulletins & ) AUTO MANUFACTURER POSITIONS ON BRAKE REPAIR ALTERNATIVES

SLIDE 17 PROCUTUSA.COM Rotor Matching Seminar 2010 FORD Replace — OK only if it can’t be machined Shims: NO Bench: NO On-Car: Pro-Cut REQUIRED since 1988 AUTO MANUFACTURER POSITIONS ON BRAKE REPAIR ALTERNATIVES

SLIDE 18 PROCUTUSA.COM Rotor Matching Seminar 2010 GENERAL MOTORS Replace — Recommended only if there’s not enough material to machine Shims: Recommended with new or bench machined rotor Bench: OK with shims Pro-Cut On-Car: ESSENTIAL EQUIPMENT since 2003 (Bulletin ) AUTO MANUFACTURER POSITIONS ON BRAKE REPAIR ALTERNATIVES

SLIDE 19 PROCUTUSA.COM Rotor Matching Seminar 2010 Nissan/Infiniti (has tightest spec in the industry – finished rotor must be <.001” Replace — Only if rotor can’t be machined with Pro-Cut Shims: NO Bench: NO Pro-Cut On-Car: ESSENTIAL EQUIPMENT (only brand to hold spec) (Bulletin BR04-003/NTB04-066) AUTO MANUFACTURER POSITIONS ON BRAKE REPAIR ALTERNATIVES

SLIDE 20 PROCUTUSA.COM Rotor Matching Seminar 2010 Widest acceptance by OEMs Patented PFM Rotor Matching Technology eliminates lateral run-out to less than.001” Fastest process time: 7-9 minutes/rotor Excellent non-directional surface finish in one pass. Rotor service time and quality consistent across all vehicle types including trucks with trapped/captured rotors ROTOR MATCHING OVERVIEW

SLIDE 21 PROCUTUSA.COM Rotor Matching Seminar 2010 Built in West Lebanon, NH, USA Only patented, fully computerized run-out compensating machines Used on vehicles from 3-lug smart cars to 10-lug dual-wheel trucks Recommended or Required by Chrysler, Ford, GM, Nissan, Toyota, Subaru (and most other manufacturers) Used by virtually all national service chains: Pep Boys, Sears, Les Schwab, Goodyear, Firestone, etc. Found in over 60% of all OEM Dealerships in the USA Over 40,000 sold worldwide –most prevalent OCL that technicians will encounter in the field PFM 9 SERIES LATHES ARE... Pro-Cut PFM 9.2DRO

SLIDE 22 PROCUTUSA.COM Rotor Matching Seminar 2010 Rotor Matching and finishing questions? Thank you for coming today!