Disc Brake System: Service and Repair

Removal
1. Raise and support vehicle.
2. Remove front wheel and tire assemblies.

Caution: During procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly.





3. Loosen the two caliper mounting bolts from the caliper support.
4. Remove caliper from caliper support.





5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flexible hose. Supporting weight of caliper by the brake fluid flexible hose, can damage the flexible brake hose.





6. Remove the pad assembly from the caliper support.





7. Loosen the two caliper support mounting bolts and remove the caliper support from the steering knuckle.





8. Loosen the two disc plate screws from the front hub assembly. Then pull the disc plate out from the front hub assembly.

Inspection
Disc plate





1. Measure thickness of disc plate.
Standard: 1.02 inch (26 mm)
Minimum: 0.94 inch (24 mm)





2. Measure runout at 0.47 - 0.63 inch (12 - 16 mm) inside from outer edge of contact surface of disc pad.
Runout: 0.002 inch (0.05 mm) Max.

Caution:
a) There must be no wheel bearing looseness.
b) Measurement location is outer edge of disc plate surface.

Disc brake pad
1. Check facing for oil or grease abnormal wear, cracks, and deterioration or damage from heat.





Measure thickness of lining.
Specified thickness: 0.41 inch (10.5 mm)
Minimum: 0.1 inch (2.5 mm)
2. Visually check for damage or wear on the guide plate.

Replacement

Notice: Perform the following steps after the replacement.
a) Fill the fluid and bleed air.
b) Check the leakage of fluid.
c) Depress the brake pedal several times, and check that the brake does not have any friction when the wheel is fumed by hand.

1. Install the disc plate to the front hub assembly before tightening the two disc plate screws.
Tightening torque: 7 - 11 ft. lbs. (10 - 15 Nm, 1.0 - 1.5 kg-m)





2. Install the caliper support to the steering knuckle and tighten the caliper support mounting bolts.
Tightening torque: 72.33 - 94.03 ft. lbs. (98 - 127.5 Nm, 10 - 13 kg-m)
3. Install the pad assembly to the caliper support.





4. Expand the piston using SST (OK130 430 017) and install the caliper into caliper support.





5. Tighten the caliper mounting bolts.
Tightening torque: 15.9 - 23.1 ft. lbs. (21.57 - 31.38 Nm, 2.2 - 3.2 kg-m)

Caution: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper bushings do not get damaged by the steering knuckle bosses.

6. Install wheel and tires.
7. Tighten hub nuts.
Tightening torque: 65 - 79 ft. lbs. (88 - 108 Nm, 9.0 - 11.0 kg-m)
8. Before moving vehicle, pump the brake pedal several times to insure vehicle has a firm brake pedal.