Brake Pad: Service and Repair

Replace brake pads when the brake pad lining is down to .078 inch (2 mm) or when the pads are greasy. When the brake pads are worn to the backing plate, the caliper may also be damaged, since the lap between the sealing ring groove and the dust cap will fracture, creating caliper to leak.




1. On calipers equipped with brake lining wear indicators, pull clip sensor cables from plug connector (52) on caliper assembly.




2. On Teves type caliper (shown), knock holding pins (41) from caliper assembly.
3. On Bendix and Girling type calipers, pull both locking eyes out of holding pins and remove holding pins.
4. Pull sensor from backing plate or out of brake linings. Simultaneously remove cross spring or lining holding spring. Replace damaged sensors, as required.




5. Using a suitable puller, pull brake pads (43) out of caliper.
6. If brake pad wear is excessive, check caliper piston for smooth operation. If pistons are hard to move, repair or replace caliper as required.

NOTE: Brake discs which are badly contaminated at the braking surface by deposits from lining (indicated by gray or blue discoloration of brake surface), must be cleaned prior to installing new break pads.




7. Using a suitable brush (030), clean caliper brake pad guide.
8. Check dust cap for cracks.

Fig. 6 Brake pad lubrication points:

9. Reverse procedure to install, noting the following.
- Coat brake pad lightly with lubricant at the points indicated by the arrows in Fig. 6. Use MolyKote Paste U, Molykote Paste G Rapid, Liqui-MolyPaste 36 or Plastilube.
- To prevent overflowing of the expansion tank when pushing pistons back in, withdraw some fluid from the expansion tank (reservoir).
- Before moving or attempting to drive the vehicle, operate the brake pad several times until pressure in the system has built up.
- Brake pads must be broke in properly. That is, the vehicle should be braked several times from 80 km/h to 40 km/h at slight pedal pressure, allowing sufficient time for the brakes to cool prior to each deceleration.

NOTE: On vehicles with pressure difference warning indicator (DDW), the warning lamp of the warning indicator may light following a brake lining (pad) change. For this reason, make sure that the releasing pin on the switch is pushed following the change of the lining. The switch is located on the master cylinder.

Special Tools:







Wedge is only needed on four piston calipers.