Dual Piston Caliper
Double piston front brake calipers, servicingWARNING: Do not re-use fasteners that are worn or deformed in normal use.
Some fasteners are designed to be used only once, and are unreliable and may fall if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
To siphon brake fluid, always use a bleeder bottle which is only used to siphon brake fluid.
Brake fluid is poisonous and must NEVER be removed by siphoning with your mouth.
Note: Install complete repair kit.
After installing the brake pads, depress the brake pedal firmly several times before moving the vehicle to properly seat the brake pads in their normal operating position.
The brakes can be tested on a commercial brake dynamometer provided the speed of the two dynamometer drive rollers is not more than 5.5 km/h (3.3 mph).
Tightening torque for the brake lines is 15 Nm (11 ft lb).
1. Torx� bolt
Always replace
25 Nm (18 ft lb)
Remove and install using commercially available Torx socket T40
Bolts are included in the repair kit for the brake pads
2. Brake disc
Always replace as a set on both wheels of an axle
Ensure adequate thickness
To remove, first unbolt brake caliper
Internally ventilated brake disc
Diameter: 245 mm (9.65 in)
Thickness: 30 mm (1.18 in)
Wear limit 28 mm (1.10 in)
3. Brake caliper
CAUTION: Do not allow the caliper to hang by the brake hose. The unsupported weight can stretch and damage the hose.
Secure the brake caliper with a piece of wire in order to relieve the stress on the brake hose.
With the exception of replacing brake pads and servicing front brake calipers, no further repairs may be performed to the brake caliper
4. Clamping spring
5. Ribbed bolt 200 Nm (148 ft lb)
Clean ribbing if re-using
6. Brake line 15 Nm (11 ft lb)
7. Retaining spring
8. Harness connector
Only on models with wear indicators
9. Brake hose
Do not disconnect the brake hose from the caliper when replacing brake pads.
10. Bolt 25 Nm (18 ft lb)
11. Bracket
Bolt to brake caliper housing
Install harness connector for brake pad wear indicator
12. Harness holder
Only on models with wear indicators
Install harness for brake pad wear indicator into harness holder
13. Brake pads
Always replace as a set on both wheels of an axle
Different left and right sides
Removing and installing, refer to Brake Pad/Service and Repair Service and Repair
With wear indicator
Once wear limit is reached (3 mm, 0.12 in), warning light in instrument panel comes on
Brake pad thickness: 14 mm (0.55 in)
Outer pads have an adhesive with a protective sheet on the backing plate; remove this sheet before installing