Front

REMOVAL
1. Remove brake master cylinder cap. Check fluid level in reservoir. Remove brake fluid until reservoir is half full. Discard removed fluid.
2. Raise vehicle on hoist.
3. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper and front disc brake rotor shield or bleeder screw fitting.
4. Remove disc brake caliper locating pin and rear brake pin retainer.
5. Lift disc brake caliper from front disc brake caliper anchor plate and front disc brake rotor. Do not pry directly against caliper piston or damage will occur.

NOTE: It is not necessary to disconnect hydraulic connections.

6. Position disc brake caliper out of the way and support it with a length of wire to avoid damaging the disc brake caliper and hose.
7. Remove outer brake shoe and lining from front disc brake caliper anchor plate.
8. Remove inner brake shoe and lining.
9. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor. Hand-sand glaze from both rotor braking surfaces using garnet paper 100A (medium-grit) or aluminum oxide 150-J (medium).

INSTALLATION

Retracting Caliper:

1. Use a 10 cm (4 inches) C-clamp and wood block 7 cm x 2.5 cm (2.75 inches x 1 inch) approximately 19 mm (0.75 inch) thick, to seat disc brake caliper hydraulic piston in its bore. This must be done to provide clearance for disc brake caliper to fit over front disc brake rotor during installation. Extra care must be taken during this procedure to prevent damage to caliper Piston.

CAUTION: Metal or sharp objects cannot come into direct contact with piston surface or damage will result.

2. Remove all rust buildup from inside of disc brake caliper (shoe contact area).
3. Install inner and outer brake shoe and lining assembly with clip-on front wheel disc brake shoe insulator into front disc brake caliper anchor plate.
4. Install disc brake caliper onto front disc brake caliper anchor plate.
5. Install disc brake caliper locating pin. Tighten to 31-38 Nm (23-28 ft. lbs.).
6. Install wheel and tire assembly. Tighten lug nut to 113-153 Nm (83-112 ft. lbs.). Use torque wrench not impact tool.

CAUTION: Failure to tighten wheel hub bolt nuts with a torque wrench in star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.

7. Lower vehicle.
8. Pump brake pedal prior to moving vehicle to position brake linings. Refill brake master cylinder.
9. Road test vehicle.