Front

CAUTION: Handle the front disc brake rotor and front disc brake caliper assemblies in such a way as to avoid damage to the front disc brake rotor and nicking, scratching, or contamination of the brake shoe and lining.

CALIPER REMOVAL
1. Raise and support vehicle.
2. 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.

3. Remove anchor plate mounting bolts.
4. Lift front disc brake caliper/front disc brake caliper anchor plate away from front disc brake rotor using rotating motion.

NOTE: To prevent damage, do not allow front disc brake caliper to hang by the front brake hose.

5. Position the front disc brake caliper out of the way.

ROTOR REMOVAL
NOTE: If excessive force must be used during front disc brake rotor removal, the disc brake rotor should be checked for lateral runout prior to installation.

1. Mark one stud and rotor with touch-up paint to ensure proper re-alignment.
2. Remove disc brake rotor assembly from wheel hub. If both front disc brake rotors are being serviced, label disc brake rotor 'left' or 'right'.
3. If additional force is required to remove disc brake rotor, apply rust penetrant to disc brake rotor/wheel hub mating surfaces. First, strike disc brake rotor between studs with a plastic hammer. If this does not work, attach 2-3 Jaw Puller and remove disc brake rotor.

ROTOR SHIELD REMOVAL
1. Using a center punch and hammer, drive the center of the rivet out.
2. Drill out the three rivets retaining the front disc brake rotor shield
3. Remove the front disc brake rotor shield.

ROTOR SHIELD INSTALLATION
1. Position front disc brake rotor shield until rotor shield mounting surfaces contact front wheel spindle mounting bosses and holes in rotor shield are aligned with holes in spindle.
2. Install new rivets using Heavy Duty Riveter D80L-23200-A or equivalent through mounting holes in front disc brake rotor shield and front wheel spindle. The rivet head should clamp the shield securely to the spindle.

ROTOR INSTALLATION
1. Install the disc brake rotor assembly on the wheel hub. If original rotor is being installed, align index marks.

CALIPER INSTALLATION

Retracting Caliper:

1. Inspect 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).

2. Install 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.

3. Make sure front disc brake rotor shield does not contact front disc brake rotor or wheel and tire assembly. Rotate wheel to visually inspect for contact.
4. 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.).
5. Lower vehicle.
6. Pump brake pedal prior to moving vehicle to position brake linings. Check and fill the brake master cylinder.
7. Road test vehicle.