Lucas
Lucas front brakes, 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 15Nm (11 ft lb).
1. Brake hose
Do not disconnect the brake hose from the caliper when replacing brake pads.
CAUTION: Do not allow the caliper to hang by the brake hose. The unsupported weight can stretch and damage the hose.
2. Clamp
3. Brake line 15 Nm (11 ft lb)
Install into caliper housing
When tightening to brake hose, counter hold on brake hose hex
4. Self-locking bolt 30 Nm (22 ft lb)
Always replace
Counterhold guide pin when loosening and tightening
5. Ribbed bolt 125 Nm (92 ft lb)
Clean ribbing if re-using
6. Brake carrier with guide pins and protective caps
Supplied as a pre-assembled replacement part with adequate amount of grease on guide pins
7. Brake disc
Always replace as a set on both wheels of an axle
To remove, first unbolt brake caliper
Resurface evenly on both sides starting from thickness when new
Non-ventilated brake disc
Diameter: 280 mm (11.02 in)
Thickness: 13 mm (0.51 in)
Wear limit: 11 mm (0.43 in)
Internally ventilated brake disc
Diameter: 280 mm (11.02 in)
Thickness: 22 mm (0.87 in)
Wear limit: 20 mm (0.79 in)
8. Brake pads
Different versions available, check with your parts department for correct application
Always replace as a set on both wheels of an axle
Removing and installing, refer to Brake Pad/Service and Repair Service and Repair
Brake pad wear limit (friction material): 2 mm (0.08 in)
Brake pad wear limit (including backing plate): 7 mm (0.28 in)
9. Heat shield
Install in piston
10. Brake caliper housing
Do not disconnect brake hose when replacing brake pads
11. Bracket
Bolt to brake caliper housing
12. Bolt 10 Nm (7 ft lb)