Front

Front Brake Pads Inspection and Replacement

CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
- Avoid breathing dust particles
- Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels.





2. Remove the brake hose mounting bolt (A) from the knuckle.
3. Hold the caliper pin with a wrench, being careful not to damage the pin boot. Remove the caliper bolt (B) with another wrench.
4. Pivot the caliper (C) up out of the way. Check the hoses and pin boots for damage and deterioration.





5. Remove the pad shims (A), pad retainers (B), and pads (C). The '99-01 models have two pairs of pad shims. The '02 model has one pair of the pad shims.





6. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate (A) thickness.
7. If the brake pad thickness is less than the service limit, replace the front pads as a set.
8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
9. Check the brake disc for damage and cracks.





10. Install the pad retainers (A).





11. Apply Molykote M77 grease or Daikalub 528D grease to both sides of the pad shims (A) and the back of the pads (B). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
12. Install the brake pads and pad shims correctly. The '99-01 models have two pairs of the pad shims. The '02 model has one pair of the pad shims. Install the pad with the wear indicator (C) on the inside.

NOTE: Check the brake fluid level, the brake fluid may overflow the reservoir if too full.





13. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliber down.
14. Pivot the caliper down into position. Hold the caliper pin with a wrench, being careful not to damage the pin boot. Install the caliper bolt (B), with another wrench, and torque it to proper specification.
15. Install the brake hose onto the knuckle.
16. Press the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.
17. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.