Brake Pad: Service and Repair

BRAKE PADS

NOTE:2WD shown, 4WD similar.










Removal

WARNING:Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING:Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION:Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
1. Check the brake fluid level in the brake master cylinder reservoir.

- If required, remove the fluid until the brake master cylinder reservoir is half full.

2. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

3.

CAUTION:Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots.

CAUTION:Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper pin bolts and position the caliper aside.

- Support the caliper using mechanic's wire.

4.
NOTE:Do not remove the anchor pins unless installing new pins.Inspect the anchor plate guide pins. They should slide in and out of the anchor plates with no binding. Check the boots for cracks or tears. If the pins do not slide easily or the boots are cracked or torn, install new boots and pins. Lubricate the pins using silicone brake caliper grease.

5.

CAUTION:Install new brake pads if they are worn past the specified thickness above the metal backing plate or rivets. Install new brake pads in complete axle sets.Inspect the brake pads for wear and contamination. See Initial Inspection and Diagnostic Overview.

6. Inspect the brake disc. Machine or install a new front brake disc as necessary. See Initial Inspection and Diagnostic Overview.

Installation

1.

CAUTION:Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads.
NOTE:If installing new brake pads, install all new hardware as supplied with the brake pad kit.
Install the 2 new brake pad clips and the 2 brake pads.






1.

CAUTION:Protect the piston and boots when pushing the caliper piston into the caliper piston bores.If installing new brake pads, using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the caliper.

2.

CAUTION:Tighten the bottom caliper bolt before tightening the top caliper bolt.

CAUTION:Make sure the caliper pin boots are correctly seated to prevent damage to the guide pins.
Position the brake caliper and install the 2 caliper pin bolts.

- Tighten to 36 N-m (3.7 kgf-m, 27 ft-lbf).

3. Fill the brake master cylinder reservoir with clean DOT 3 brake fluid.

4. Test the brakes for normal operation.