Front Disc Brake Pads Replacement

Front Disc Brake Pads Replacement

Removal Procedure

Caution: Refer to Brake Dust Caution.

Caution: Refer to Brake Fluid Irritant Caution.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice.

1. Use a siphon in order to remove half of the brake fluid from the master cylinder reservoir.
2. Raise and support the vehicle.
3. Remove the tire and wheel assembly from the vehicle.




4. Install a large C-clamp over the brake caliper. Position the ends of the C-clamp against the rear of the caliper body and against the outer brake pad.
5. Tighten the C-clamp in order to compress the caliper piston into the caliper bore.
6. Remove the C-clamp from the caliper.




7. Remove the 2 caliper bolts.





Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

8. Remove the caliper housing (2) from the caliper bracket. Support the caliper with a wire (1) in order to prevent damage to the brake hose.




9. Remove the 2 brake pads (6,10).
10. Remove the inner pad wear indicator (3) from the inner pad.
11. Remove the outer pad wear indicator (5), if equipped, from the outer pad.
12. Remove the 2 insulators (1,7).
13. Remove the 2 pad insulators (2,8).

Important: Note the location of the upper retainer and the lower retainer. The upper retainer is not interchangeable with the lower retainer.

14. Remove the 2 brake pad retainers (4,9).

Inspection Procedure




1. Inspect the brake pads for wear. If the pad thickness is less than specification, replace the disc brake pads in axle sets.

The minimum brake pad lining thickness is 1 mm (0.039 in).




2. Clean the 2 brake pad retainers (4,9). Inspect the retainers for the following conditions:
^ Sufficient rebound
^ No deformation
^ No cracks
^ No wear
^ No rust
^ No dirt
If the retainers meet the above conditions, re-use the retainers.
3. Clean and inspect the disc brake hardware. Replace components if necessary.
4. Clean and inspect the caliper. Repair or replace components as necessary.

Important: Refinish or replace the rotor ONLY if the condition of the rotor requires service. DO NOT refinish the rotor if the brake pads are the only components requiring service.

5. Measure the brake rotor thickness. Refinish or replace the rotor as necessary.
6. Measure the brake rotor thickness variation. Refinish or replace the rotor as necessary.
7. Inspect the surface of the brake rotor. Refinish or replace the rotor as necessary.
8. Measure the brake rotor assembled lateral runout. Refinish or replace the rotor as necessary.

Installation Procedure




1. If the caliper piston is not compressed into the caliper bore, complete the following steps:
1. Place an old brake pad (2) or a block of wood against the caliper piston.
2. Install a large C-clamp over the body of the brake caliper.
3. Position the ends of the C-clamp against the rear of the caliper body and against the pad or the wood.
4. Tighten the C-clamp in order to compress the caliper piston into the caliper bore.
5. Remove the C-clamp.




2. Install the upper brake pad retainer (4) to the caliper bracket.
3. Install the lower brake pad retainer (9) to the caliper bracket.
4. Install the inner wear indicator (3) to the inner pad (10).
5. Install the outer wear indicator (5), if equipped, to the outer pad (6).
6. Apply disc brake grease to both sides of the inner pad insulator (2).
7. Install the inner pad insulator to the inner pad.
8. Install the inner insulator (1) to the inner pad insulator.
9. Install the inner brake pad to the caliper bracket with the wear indicator facing upward.
10. Apply disc brake grease to both sides of the outer pad insulator (8).
11. Install the outer pad insulator to the outer pad (6).
12. Install the outer insulator (7) to the outer pad insulator.
13. Install the outer brake pad to the caliper bracket.




14. Install the caliper housing (10) to the caliper bracket (14).

Notice: Refer to Fastener Notice.

15. Install the caliper bolts (11,18).

Tighten the bolts to 34.3 N.m (25.30 lb ft).

16. Install the tire and wheel assembly to the vehicle.
17. Lower the vehicle.

Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

18. With the engine OFF, gradually apply and release the brake pedal several times in order to position the caliper pistons and the brake pads.
19. Fill the master cylinder fluid reservoir.
20. Burnish the pads and the rotors.