Front

WARNING:
- Never use an air hose or dry brush to clean brake assemblies.
- Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.

1. Loosen the front wheel nuts slightly, then raise the vehicle and support it on safety stands. Remove the front wheels.





2. Remove the caliper bolt (pin A), and pivot the caliper up out of the way.

NOTE: Check the hoses and pin boots for damage and deterioration.





3. Remove the pad shims, pad retainers and pads.

NOTE: When the caliper is equipped with pad shims, replace the shims together with the pads as a set.





4. Using vernier calipers, measure the thickness of each brake pad lining.

Brake Pad Thickness:
Standard: 12.0 - 13.0 mm (0.47 - 0.51 inch)
Service Limit: 1.6 mm (0.06 inch)

NOTE: Measurement does not include pad backing plate thickness.

5. If the brake pad thickness is less than service limit, replace the front pads as a set.
6. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
7. Check the brake disc for damage and cracks.





8. Install the pad retainers.





9. Apply Molykote M77 grease to the inner side of the pad shims and the back of the pads. Wipe excess grease off the shim.
10. Install the brake pads and pad shims correctly.

WARNING:
- When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.
- Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.

NOTE: Install the pad with the wear indicator on the inside.





11. Push in the piston 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 caliper down.
12. Pivot the caliper down into position, then install caliper bolt (pin A) and tighten it.

CAUTION: Be careful not damage the pin boot when pivoting the caliper down.

13. Depress the brake pedal several times to make sure the brakes work, then road-test.

NOTE: 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.

14. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.