Front Brake System Repair - Disassembly

1. Raise the vehicle on a hoist. Refer to the 1989 XR4Ti Shop Manual, Section 50-04 for hoisting procedure.

2. Remove the front tire and wheel assemblies. Refer to the 1989 XR4Ti Shop Manual, Section 11-01 for service details.

3. Disconnect the brake pad wear sensor connector.

4. Remove the caliper to anchor plate attaching pins.

Figure 1:

5. Suspend the caliper from the body with a piece of wire to prevent the flex hose from becoming damaged, Figure 1.

6. Remove the caliper anchor bracket retaining bolts and remove the anchor bracket from the spindle carrier.

7. Remove the inner and outer brake pads from the caliper.

8. Using a disc brake pad spreader, carefully force the piston into the caliper housing.

9. Remove the rotor retaining clip and the rotor from the hub.

10. Remove the cotter pin and nut attaching the tie rod end to the spindle carrier.

a. Discard the cotter pin.

b. Separate the tie rod end from the spindle carrier using a tie rod end remover (T85M-3395-A) or equivalent.

Figure 2:

11. Remove the nut, washer and pivot bolt attaching the control arm to the crossmember, Figure 2.

12. Remove the nut, front washer and cover attaching the stabilizer bar to the control arm.

13. Remove the cotter pin and attaching nut from the lower control arm ball joint. Throw away the cotter pin.

14. Remove the lower control arm from the vehicle.

15. Remove the rear washer and cover from the stabilizer bar.

16. Remove and throw away the pinch bolt from the spindle carrier.

Figure 3:

a. Insert the spindle carrier lever (T85M-3206-A) or equivalent into the carrier slot, Figure 3.

b. Rotate the spindle carrier lever 90~.

c. Slide the spindle carrier assembly off the strut.

d. Remove the spindle carrier lever.