Disc Brake Hardware Replacement - Front

Disc Brake Hardware Replacement - Front (25/3500 Series)

Caution: Refer to Brake Dust Caution in Service Precautions.

Removal Procedure





1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Remove the tire and wheel assembly.
5. Compress the brake caliper pistons.
1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad.
2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores.
3. Remove the C-clamps from the caliper.





6. Remove the brake caliper bolts.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

7. Notice: Refer to Brake Caliper Notice in Service Precautions.

Remove the caliper from the caliper bracket. Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.





8. Remove the brake pads from the caliper bracket.
9. Remove the brake pad retainers.
10. Inspect the disc brake hardware.





11. Remove the caliper pin boots (4) from the caliper bracket (3).

Installation Procedure





1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper pin boots (4) to the caliper bracket (3).





3. Install the brake pad retainers to the caliper bracket.
4. Install the brake pads.





5. Notice: Refer to Fastener Notice in Service Precautions.

Install the caliper to the caliper bracket.
6. Install the brake caliper bolts.
Tighten the bolts to 108 Nm (80 ft. lbs.).
7. Install the tire and wheel assembly.
8. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the caliper pistons and pads.
11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary.