Front

Brake Pads

Material:

Front Brake Disc System:

Removal

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled.

2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, Maintenance/Service and Repair.

3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets.

Inspect the brake pads for wear or contamination and install new pads as necessary.

4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring.

Remove the anchor housing spring.

5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity.

For the LH brake caliper, release the lower portion of the anchor housing spring.
^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity.

6. Rotate the spring upward then remove it from the brake caliper.

7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs.

For RH brake caliper, release the upper portion of the anchor housing spring.
^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity.

8. Rotate the spring downward then remove it from the brake caliper.

9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur.

Remove the guide pins and position the caliper aside.
^ Remove the zero-drag spring.
^ Remove and discard the brake caliper-to-anchor plate guide pins and boots.
10. Remove the brake pads from the brake caliper.

11. NOTE: Use a wood block or a used brake pad to protect the brake caliper piston boots.

Compress the brake caliper pistons.
12. Inspect the brake disc and resurface or install a new brake disc as necessary.

Installation
1. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach.
2. Install new brake hardware as follows:
^ Install the guide pin bushings into the caliper bores.
^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads.
^ Push the guide pins into the bushing.
3. Install the inboard brake pad into the brake caliper.
4. Remove the protective paper from the outboard brake pad and install it into the brake caliper.
5. Install the brake caliper on the brake disc.
6. Install the guide pins and install the dust caps.
^ Tighten to 55 Nm (41 ft. lbs.).
^ Install the guide pin boots.
7. Install the zero-drag spring.

NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first.

8. Install the anchor housing spring.
1 Insert the tab of the anchor housing spring into the brake caliper cavity.
2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity).

9. Rotate the anchor housing spring and position the upper portion onto the anchor plate.

10. Position the other anchor housing spring portion onto the brake caliper anchor plate.
11. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities.

12. NOTE: The latch MUST be positioned as shown.

Verify that the anchor housing spring is correctly latched.
13. Apply the brake several times to verify correct brake operation.