Front
REMOVAL1. Remove master cylinder cap and check fluid level in reservoir. Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
2. Raise and support vehicle.
3. Remove wheel and tire assembly from rotor mounting face. Use care to avoid damage or interference with front disc brake rotor shield or wheel cylinder bleeder screw.
NOTE: It is not necessary to disconnect hydraulic connections.
4. Remove anchor plate mounting bolts.
5. Lift front disc brake caliper/front disc brake caliper anchor plate away from front disc brake rotor using rotating motion.
6. Remove outer brake shoe and lining assembly from front disc brake caliper assembly by sliding brake shoe and lining in anchor away from outer leg to disengage from front disc brake caliper anchor plate. Remove outer brake shoe and lining.
7. Remove inner brake shoe and lining assembly by sliding brake shoe and lining in anchor away from caliper piston disengaging it from the front disc brake caliper anchor plate. Remove inner brake shoe and lining and anti-rattle clip.
8. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor.
9. Inspect piston boot and caliper pin boots for damage and replace as necessary.
10. Support the front disc brake caliper assembly in a manner that will not stretch or damage the front brake hose.
INSTALLATION
Retracting Caliper:
NOTE: The rubber caliper insulators and the plastic sleeves (if equipped) must be replaced when brake shoes and linings are replaced.
1. Use a 10 cm (4 inch) C-clamp and wood block 70 mm x 25 mm (2-3/4 inch x 1 inch) and approximately 19 mm (3/4 inch) thick to seat caliper piston in its bore. This must be done to provide clearance for front disc brake caliper assembly to fit over front disc brake rotor during installation.
NOTE: Front disc brake rotor casting allows disc brake pad anti-rattle clip to be installed one way only. RH and LH hold-down springs are identical but installed in opposite directions.
2. Thoroughly clean any residue from insulator from front disc brake caliper and brake shoe and lining abutments as necessary. Make certain disc brake pad anti-rattle clip is seated in brake shoe and lining inspection opening. Hold-down springs must be installed from lining side.
3. Peel protective paper from insulator on the brake shoe and lining. The insulator will be black after the paper has been removed. This pressure-sensitive adhesive insulator functions to reduce noise and care should be exercised to avoid contamination on the adhesive surface prior to installing the brake shoe and lining in the front disc brake caliper assembly.
4. Engage the shoe in the anchor by engaging the side opposite the disc brake pad anti-rattle clip. Depress the other end of brake shoe and lining assembly to compress the hold-down spring and engage the shoe in the front disc brake caliper anchor plate. Both inner and outer brake shoes and linings are installed in this manner.
5. Inspect front disc brake caliper/front disc brake caliper anchor plate assembly to confirm brake shoe and lining assemblies are properly installed and that lining faces rotor opening.
NOTE: It is important to use correct bolt (M 12 x 1.75 g property class 10.9, 30-31 mm long).
6. Install front disc brake caliper/anchor plate mounting bolts through front wheel spindle and hand-start. Tighten to 130 Nm (96 ft. lbs.).
CAUTION: Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
7. Install wheel and tire assembly, using Rotunda Accutorq Lug Nut Sockets 164-R0303 or equivalent on 1/2 inch drive air impact wrench. A torque wrench may be used. Tighten lug nuts to 115-142 Nm (85-104 ft. lbs.).
8. Lower vehicle.
9. Pump brake pedal prior to moving vehicle to position brake linings. Refill the brake master cylinder.
10. Road test vehicle.