Front
Front Brake Pad Inspection and ReplacementCAUTION:
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.
Inspection
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheels.
3. Check the thickness (A) of the inner brake pad (B) and outer brake pad (C). Do not include the thickness of the backing plate.
4. If the brake pads thickness is less than the service limit, replace the front brake pads as a set.
5. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels.
Replacement
1. Remove some brake fluid from the master cylinder.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations.
3. Remove the front wheels.
4. Remove the brake hose bracket mounting bolt (A).
5. Remove the flange bolt (B) while holding the lower caliper pin with a wrench being careful not to damage the pin boot, and pivot the caliper (C) up out of the way. Check the hose and pin boots for damage and deterioration.
6. Remove the pad shims (A) and brake pads (B).
7. Remove the pad retainers (A).
8. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks.
9. Inspect the brake disc, and check for damage and cracks.
10. Clean and install the pad retainers.
11. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of outer pad shim C, inner pad shim B, both sides of inner pad shim A, the back of brake pads (D), and the other areas indicated by the arrows. Wipe excess assembly paste off the shims and brake pads. Contaminated brake discs or brake pads reduces stopping ability. Keep grease and assembly paste off the brake discs and brake pads.
12. Install the brake pads and pad shims correctly. Install the pad with the wear indicator (E) on the top inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
13. Push in the piston (A) so that the caliper will fit over the brake pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down.
14. Pivot the caliper down into position. Install the flange bolt (B), and tighten it to the specified torque while holding the lower caliper pin (C) with a wrench being careful not to damage the pin boot.
15. Install the brake hose bracket mounting bolt, and tighten it to the specified torque.
16. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
17. Press the brake pedal several times to make sure the brakes work.
NOTE: Engagement 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.
18. Add brake fluid as needed.
19. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then check for leaks.