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8 Brakes

8-2 Inspection specifications

Technical information

IMPORTANT Any parts that require removal or disassembly in order to carry out the inspection of brakes and brake components must be removed or disassembled.

Exceptions to this requirement are as follows:

a) no removal or disassembly is required for vehicles presented for re-registration that were manufactured before 1991 and previously registered in New Zealand before 1 January 1991.

b) For new vehicles and scratch-built low volume vehicles, it is not necessary to disassemble any brake
components.

c) For vehicles with rear drum brakes that are less than two years old and that have travelled less than 40,000km, only the front brakes must be disassembled initially. If the front brakes are up to standard, and there are nosigns of problems with the rear brakes, disassembly of the rear brakes is not required.

d) No removal or disassembly is required for class LA and LB vehicles, new, used or being re-registered.

Procedure


Entry-level brake inspection process for class LC, LD, LE vehicles, and group M or N light vehicles

The vehicle inspector must personally carry out the brake inspection of all vehicles according to the following specifications. The alternative method for motorcycles may be used if the vehicle inspector is unfamiliar with the disassembly or reassembly of the braking system.

Master cylinder

1. Check the condition of the brake fluid in the master cylinder reservoir, and calliper or wheel cylinder for contaminants. If there are visible signs of dirt in the fluid, the fluid must be replaced.

2. Check the master cylinder for leaks.

Underbody brake components

1. Brake components underneath the vehicle must be inspected using a hoist, pit or ramp that allows the vehicle inspector to comfortably walk under the vehicle.

2. Check the park brake cable by examining exposed cable for signs of knotting, corrosion or fraying or the use of auxiliary tensioning devices.

3. Examine any brake rods for excessive corrosion or wear.

Wheels, brake drums and disc pads

1. Remove all wheels, brake drums and disc pads.

a) Only the front brakes need to be disassembled initially, if the vehicle:

  • is less than two years old, and
  • has travelled less than 40,000km, and
  • is fitted with drum brakes at the rear.

Provided there are no problems detected with the front brakes and the rear brakes exhibit no external sign of a problem (eg uneven braking, leaks, noises), no further disassembly is required.

b) Brake components do not need to be disassembled during the entry certification inspection if the vehicle is new (Note 1) or a scratch-built low volume vehicle.

Note 1

‘New’ means a vehicle that has not been registered and operated in any country, and has not been operated on a road in any country as a demonstration or courtesy vehicle or used for training or test purposes. It must not be a scratch-built vehicle that contains components which have been fitted to a vehicle operated on a road in any country.

c) Any brake discs or drums and their friction materials, which are used for park brakes only, do not have to be inspected in detail, or have compliance verified. No further disassembly is required provided the brakes do not show any external signs of a problem and meet performance and condition requirements set out in the VIRM: In-service certification section 8-1.

2. Check the run out of the disc rotors, the minimum thickness of the discs and any variation in disc thickness using calibrated measuring equipment (Note 2).

3. Check the drums for ovality using calibrated measuring equipment.
Measurements must be checked against the manufacturer’s specifications. If the manufacturer’s specifications are not available, the following maximum runout and ovality are permitted:

  • runout on a disc brake rotor with a single acting hydraulic piston 0.1mm
  • runout on a disc brake rotor with opposing hydraulic pistons 0.2mm
  • ovality on a brake drum for light vehicles 1.0mm.
Note 2

If an entry certifier wishes to use a roller brake machine to detect disc/rotor runout, they must be able to demonstrate this ability to a Transport Agency officer.

If machining is required, both of the drums or discs on a common axis must be machined. If it is found that a disc brake rotor requires machining or replacing, the brake friction material that was originally fitted to the vehicle may be re-used, provided it is within safe tolerance of the vehicle manufacturer’s specifications. The entry certifier must consider the thickness and condition of the remaining brake friction material, and whether or not the vehicle manufacturer permits the re-fitting of brake friction material to new or re-surfaced brake rotors.

Wheel cylinders and callipers

1. Check wheel cylinders and callipers for fluid leaks.

2. Check that the calliper or cylinder pistons have not seized, and are able to slide or swing on their mountings as appropriate.

Brake pipes

1. Ensure that brake pipes are secure and supported.

Hoses and connections

1. Inspect all hoses and connections (under pressure) for condition. Flexible brake hoses must be rejected if:

  • they leak brake fluid, or
  • they are insecure, or
  • they bulge under pressure, or
  • they are twisted, or
  • they have been stretched, or
  • the outer covering is chafed or cracked, particularly in the area of the crimp.
Brake friction material

1. Visually inspect the brake friction material to verify that the material was supplied by the vehicle manufacturer. The name or logo of the vehicle manufacturer or a brake friction material manufacturer (listed in Figure 8-2-1) will be marked on the backing plate or the edge of the friction material.

If the material cannot be identified as being supplied by the vehicle manufacturer, the vehicle must not be certified until replacement brake friction material has been fitted, which:

  • has been supplied by a recognised supplier (Note 3), or
  • is accompanied by a statement completed by the supplier (see Reference material 42), or
  • is accompanied by a ‘Brake repair declaration’ (see Reference material 42) completed by a recognised brake repairer.

A correctly completed ‘Brake repair declaration’ is acceptable evidence for replaced brake friction material.

If the brake friction material fitted to a vehicle is not known to be original equipment (OE), it may be accepted if it was made by a manufacturer that is known to produce OEM or OES brake parts.

If brake friction material does not meet these criteria, it must be removed and replaced with parts that return the vehicle’s brakes to within safe tolerance of the manufacturer’s specifications. When disc pads or linings are replaced, the material on both the left and right side of an axle must be replaced using identical material with the same co-efficient of friction.

Table 8-2-1. Limits for wear on brake friction material

Material

Minimum thickness

Disc pads

3.0mm

Shoe linings (bonded)

2.0mm

Shoe linings (riveted)

2.0mm above the head of the rivet minimum thickness

Note 3

A recognised supplier is a supplier recognised by the entry certifier as being reputable and competent to supply material that ensures the braking system will be returned to within safe tolerance of its state when manufactured.

Note 4

These limits for wear do not apply if the manufacturer has specified a greater minimum thickness for specific vehicle makes and models.

Note 5

For further information, please refer to Technical bulletin 1 – Replacement parts.

Important: Entry certifiers are required to include a regular audit of brake repairers in their procedures to ensure that information contained in declarations is correct.

Markings not found in published data

Where brake friction material is found with markings that cannot be found in published data, but the entry certifier believes the material to be OEM (or acceptable manufacturer’s alternative) and otherwise fit for further service, it can be accepted. The entry certifier will need to provide evidence of how they determined that the friction material is OEM (or acceptable manufacturer’s alternative) (if asked).

Reassembly

Where components are removed as part of the inspection process, an entry certifier must have procedures in place to ensure that those components are re-assembled correctly.

Brake performance

1. Once components have been accepted, carry out a service brake system performance test using an NZTA-approved brake machine.

2. Record the braking effort achieved.

3. Check that the performance meets the requirements specified in the VIRM: In-service certification, section 8-1.

Re-checking brakes that fail inspection

If a vehicle is failed due to brake imbalance on one or more axles, each axle in question must be re-checked, as the failure may have occurred on either side, not just the side where brake force was lower.

If a vehicle is failed due to poor performance, the whole brake system must be re-checked to ensure that the repair has not affected other brakes and impaired the vehicle’s braking performance.

Vehicles returning for recheck following brake repair are not expected to be dismantled again for invasive inspection if a declaration from a recognised brake repairer is supplied. A sample Brake repair declaration is shown in Reference material 42.

Note 6

Brake parts that meet UN/ECE Regulation 90R are acceptable for vehicles undergoing entry certification. The vehicle inspector must retain documented evidence that the brake parts meet UN/ECE 90R and are suitable for the particular vehicle (in the location where they are fitted) on the vehicle file.

Alternate method for motorcycle brake inspections

In cases where a vehicle inspector is not familiar with the disassembly or reassembly of the motorcycle’s braking system, a relevant person or company, recognised by the entry certifier as being reputable and competent to carry out this work, may be employed to strip, inspect and reassemble motorcycle brake systems in accordance with the above inspection specifications.

This recognised person or company must supply the entry certifier with documentation confirming that the brake system and components are within safe tolerance of their state when manufactured.

If the motorcycle is required to comply with an approved brake standard, the documentation must also confirm that the brakes still comply with the original equipment brake standard to which the motorcycle was manufactured.

The recognised person or company must issue a declaration confirming that:

1. the motorcycle brake system has been dismantled, and

2. all brake components have been inspected, and

3. measurements have been taken and recorded, and

4. the brake system has been reassembled with no repairs required

OR

any component(s) not within safe tolerance of the manufacturer’s specifications is repaired or replaced, and the brake system has been reassembled.

If the motorcycle brake components are dismantled away from the inspection site, the brake component measurements must be recorded by the recognised person or company, or the vehicle inspector must be present during the dismantling process to record details.

The motorcycle owner/importer may take the vehicle to the recognised person or company.

Tables and images


Figure 8-2-1. Recognised brake friction material manufacturers (Note 7)

suppliers

Table 8-2-2. Approved brake parts suppliers (Note 7)

Legal name of business

Trading name used on invoice

Allparts International Ltd

Allparts International Ltd

Apex Brake and Clutch Ltd

Apex Brake and Clutch Ltd

Auto Brake and Clutch Ltd

Auto Brake and Clutch Specialists

Auto Brake and Clutch Supplies Ltd

Auto Brake and Clutch Supplies Ltd

Auto Brakes Ltd

Auto Brakes Ltd

Auto Replacements 1994 Ltd

Auto Replacements 1994 Ltd

Auto Trail Ltd

Auto Trail Ltd

Autolines NP Ltd

Autolines Auto One

Automotive Brake and Clutch Ltd

Automotive Brake and Clutch Ltd

Automotive Driveline 1992 Ltd

Automotive Driveline 1992 Ltd

Automotive Partzio Ltd

Partzio (East Tamaki Ltd)

Automotive Partzio Ltd

Partzio (Otahuhu Ltd)

Automotive Supplies NZ Ltd (including AutoStop and AutoStar)

Automotive Supplies NZ Ltd

Bay City Motor Co Ltd

Bay City Motor Co Ltd

Belfor Automotive Centre Ltd

Belfor Automotive Centre Ltd

Brake and Clutch Rebuilders Ltd

Brake and Clutch Rebuilders Ltd

Brake and Transmission Ltd

Brake and Transmission NZ Ltd

Brakes and Spares Ltd

Brakes and Spares Ltd

Challenge Auto Parts

Challenge Auto Parts

Cockram Motors (Chch) Ltd

Cockram Nissan

Collins Motors Ltd

Collins Auto Parts and Accessories

Cycle and Carriage (North Shore) Ltd

Kia Motors New Zealand

Daihatsu New Zealand Limited

Daihatsu New Zealand Limited

Direct Auto One

Direct Auto One

EBC Brakes NZ Ltd

EBC Brakes NZ

Extreme Distributors Ltd

Extreme Automotive Distributors

Forward Specs (2000) Ltd

Forward Specs (2000) Ltd

Garland Motors

Whakatane Auto One

Holdaways Limited

Holdaways Ltd

Holden New Zealand Ltd

Holden New Zealand Ltd

Honda New Zealand Ltd

Honda New Zealand Ltd

Import Part Specialists Ltd

Import Part Specialists Ltd

Independent Brake Supplies NZ Ltd

Independent Brake Supplies NZ Ltd

Interpart Ltd

Interpart Ltd

Jaycon Engineering Ltd

MP Auto Parts

Jeffrey Gong, T/A Callahan Auto SupplyCallahan Auto Supply

John Patton Ltd

Thames Auto One

Johnson Piston Rings Ltd

Johnson Piston Rings

Lambert Brake and Clutch Ltd

Lambert Brake and Clutch Ltd

Le Freins Ltd

Autosafe Taupo

MacDonald Halligan Motors Ltd

MacDonald Halligan Motors Ltd

Master Part Automotive Products (1997) Ltd

0800 Brakes

Master Part Automotive Products Ltd

Master Part Brake and Clutch

Mintoft and Heenan Ltd

Freemans Auto One

Muffler and Brake Ltd

Muffler and Brake Ltd

Murray McLean Motorcycles Services Ltd

Murray McLean Motorcycles Services Ltd

Napier Auto Supplies (1980) Ltd

Napier Auto Supplies

Nelson Brake Services Ltd

Nelson Brake Services Ltd

New Zealand Brake Company Ltd

Brake Co

Orton Motor 1990 Ltd

Ruts Auto Brake, Clutch

Owens Suspension and Brake Specialists Ltd

Owens Suspension and Brake Specialists Ltd

Partmaster Ltd

Partmaster

Pembroke Fram Ltd

Union Yamaha

Precision Brake and Clutch Services Ltd

Precision Brake and Clutch Services Ltd

R and J E Hull Ltd

Brake Specialists

Rawson Parts Ltd

Partnership Auto One

Red Baron (NZ) Ltd

 

Redwood Investments Ltd

Bikes ’n’ Bits

Repco Auto Parts Ltd (incorporating Appco Auto Parts and DAS Car Parts)

Repco New Zealand

River City Auto World

Wanganui Toyota

Robbie’s Speedy Exhaust and Brakes Shop Ltd

Robbie’s Speedy Exhaust and Brake Shop Ltd

RTJ Industries

Brake Service Centre

Safe R Brakes Ltd

Safe R Brakes Ltd

SAS Autoparts LimitedSAS Autoparts

Segedins Auto Parts Ltd

Segedins Auto Parts Ltd

Sims Brake Services Ltd

Sims Brake Services Ltd

Southern Brakes and Driveline Ltd

Southern Brakes and Driveline Ltd

Speedy Parts (NZ) Ltd

Speedy Parts (NZ) Ltd

Sterling Brake and Clutch Specialists

Sterling Brake and Clutch Specialists

Styles Autoparts Ltd

Hawera Autospares

Suvic Engineering Ltd

Suvic Engineering Ltd

T B and J F Bell Partnership

Redhills Benz

Taupo Auto One Ltd

Taupo Auto One

Transport Brake and Clutch Ltd

Transport Brake and Clutch

Triumph Promotions Ltd

Jim Wright Nissan

Vehicle Testing and Compliance Ltd

Vehicle Testing and Compliance Ltd

Waikato Bonding Services Ltd

 

Waikato Clutch and Brake Specialists Ltd

Waikato Clutch and Brake Specialists Ltd

Whakatane Brake and Clutch Centre Ltd

Whakatane Brake and Clutch Centre Ltd

W. White Wholesale Ltd.

Whites Powersports

Note 7

If you would like information added to this page please email vehicles@nzta.govt.nz with the following information:

  • documentation from the manufacturer proving the parts meet the requirements of the Land Transport Rule: Light Vehicle Brakes 2002, section 3.3(3) (ie that they comply with UN/ECE Regulation 90)
  • the manufacturers logo
  • the legal name of your business and the trading name used on invoices.

The Transport Agency will review your submission and add to this page if satisfied.

Page amended 1 June 2018 (see amendment details).