Front Brakes, Servicing (Fn-3)
Front brakes, servicing
Notes:
^ install complete repair kit.
^ After replacing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
^ When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
^ Wheel bolt tightening torque: 120 Nm).
^ Check brake caliper for freedom of movement by sliding to side.
1. Brake hose
- Do not disconnect when removing brake pads
2. Protective cap
- Remove
3. Guide pins, 25 Nm
4. Brake line, 15 Nm
- Install in brake caliper housing
- Attach to brake hose. Counter hold on brake hose hex when attaching
- Make sure lugs are properly seated in retainer grooves
5. Brake caliper housing
Note: Check brake caliper for freedom of movement by sliding to side.
6. Ribbed bolt W/washer assembly, 120 Nm
- Clean ribs if reusing
7. Brake carrier
- Bolt to wheel bearing housing
8. Brake pads
Note: Inner pad (with spring) is marked with an arrow. The arrow must point in the direction of forward rotation of the brake disc when installed. Noise may result from incorrect installation.
- Remove adhesive foil from backing plates on outer brake pads before installing
- Both pairs of brake pads on front axle must always be replaced together
- Removing and installing, Refer to Brake Pads.
Wear limit: 2 mm
Wear limit: 7 mm (including backing plate)
Note: Always clean brake caliper thoroughly before installing new brake pads (must be free of grease). Be especially careful to remove any residual adhesive foil on the surface of the outer brake pads.
9. Retaining spring
- Insert in both holes of brake caliper housing
Note: Retaining spring must be pressed under brake carrier after it is inserted in both holes. if the spring is improperly installed, the brake caliper cannot adjust to compensate for wear on the outer brake pad. This will cause the brake pedal travel to increase.
10. Brake disc
- Pads on both sides of axle must always be replaced together
- Remove brake caliper before removing
- Internally ventilated brake disc: 288 mm for 15".
- Internally ventilated brake disc: 312 mm for 16"
- Brake disc thickness: 25 mm
- Wear limit: 23 mm
- Pads on both sides of axle must always be replaced together
- Brake pads are different; inner pad has retaining spring
11. Bracket
- Bolt to brake caliper housing
12. Hexbolt, 10 Nm
Brake pads, removing and installing
Removing
Note: If re-using brake pads, mark them so that they can be installed in their original positions to prevent uneven braking.
- Remove protective caps.
- Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove.
- Remove both guide pins from brake caliper.
- Remove brake caliper housing and support so that the weight of the brake caliper does not burden or damage the brake hose.
- Remove brake pads from brake caliper housing or from brake carrier.
Installing
Note: Press piston back into caliper housing using resetting too/ before inserting new brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.
- Press piston back.
- Insert brake pad with retaining spring in brake caliper housing.
Note: Inner pad (with spring) is marked with an arrow. The arrow must point in the direction of forward rotation of the brake disc when installed. Noise may result from incorrect installation.
- Remove protective foil on backing plate of outer brake pad.
- Install outer brake pad on brake carrier.
- Install brake caliper housing in brake carrier using both guide pins (25 Nm).
- Install both protective caps.
- Install retaining spring in brake caliper housing.
Note: After installing brake pads and before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
- Check brake fluid level and top off, if necessary.