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 vehicle on hoist.
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
4. Remove anchor plate mounting bolts.
NOTE: It is not necessary to disconnect hydraulic connections.
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 lining assembly from front disc brake caliper assembly by sliding brake lining in anchor away from outer leg to disengage from front disc brake caliper anchor plate. Remove outer brake lining.
7. Remove inner brake lining assembly by sliding lining in anchor away from caliper piston disengaging it from the front disc brake caliper anchor plate. Remove inner 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:
1. Use a 10 cm (4 inches) 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.
2. Thoroughly clean any residue from insulator from front disc brake caliper and brake lining abutments as necessary. Make certain disc brake pad anti-rattle clip is seated in brake lining inspection opening. Hold-down springs must be installed from lining side.
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.
3. Peel protective paper from insulator on the brake 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 lining in the front disc brake caliper assembly.
4. Engage the pad in the anchor by engaging the side opposite the disc brake pad anti-rattle clip. Depress the other end of brake lining assembly to compress the hold-down spring and engage the pad in the front disc brake caliper anchor plate. Both inner and outer linings are installed in this manner.
5. Inspect front disc brake caliper/front disc brake caliper anchor plate assembly to confirm lining assemblies are properly installed and that lining faces rotor opening.
6. Install front disc brake caliper/anchor plate mounting bolts through front wheel spindle and hand-start. Tighten to 130 Nm (96 ft. lbs.)
NOTE: It is important to use correct bolt (M 12 x 1.75 g property class 10-9, 30-31 mm long).
7. Install wheel and tire assembly, using Rotunda Accutorq Lug Nut Sockets 164-RO303 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.).
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.
8. Lower vehicle.
9. Pump brake pedal prior to moving vehicle to position brake linings. Refill the brake master cylinder.
10. Road test vehicle.