Disc Brake System: Service and Repair

FRONT DISC BRAKE





COMPONENTS

REMOVAL
1. Raise front of vehicle and properly support it.
2. Remove front wheels.
3. Remove two bolts and remove caliper.
4. Remove brake pads and guide plate.
5. Measure brake pad thickness.
Minimum brake pad thickness: 0.08 inch (2.0 mm)
6. Prepare to catch any brake fluid. Disconnect brake hose using a flare nut wrench.
7. Remove two bolts and supporting plate.
8. Measure rotor thickness at four or more places.
Minimum rotor thickness: 0.86 inch (22 mm)
9. Mount a dial indicator and measure runout at the outer braking contact edge of the rotor.
Minimum runout: 0.002 inch (0.06 mm)

NOTE: Excessive runout could be caused by a loose wheel hub bearing.

10. To remove rotor, remove two mounting screws with an impact driver.
11. Resurface of replace rotor as required.

INSPECTION
DISC BRAKE PAD
1. Check facing for oil or grease abnormal wear, cracks, and deterioration or damage from heat. Measure thickness of lining.
Specified thickness: 0.39 inch (10 mm)
Minimum: 0.08 inch (2.0 mm)





2. Visually check for damage or wear on the guide plate.

DISC PLATE





1. Measure thickness of disc plate.
Standard: 0.94 inch (24 mm)
Minimum: 0.86 inch (22 mm)





2. Measure runout at 0.32 - 0.47 inch (8 - 12 mm) inside from outer edge of contact surface of disc pad.
Runout: 0.002 inch (0.06 mm) Max.

CAUTION:
^ There must be no wheel bearing looseness.
^ Measurement location is outer edge of disc plate surface.

INSTALLATION
1. Mount a new or repaired rotor on hub and fasten with two mounting screws.
2. Install the supporting plate, and install the guide plate to the supporting plate.
Tightening torque: 57 - 75 ft. lbs. (78 - 102 Nm, 8.0 - 10.4 kg-m)
3. Connect the brake hose to the caliper using a flare nut wrench.
Tightening torque: 9 - 13 ft. lbs. (13 - 18 Nm, 1.3 - 1.8 kg-m)





4. Push the piston back into the caliper bore by using SST.
5. Position brake pads in supporting plate cavity and install caliper onto supporting plate.
6. Install two bolts.
Tightening torque: 61 - 68 ft. lbs. (83 - 93 Nm, 8.5 - 9.5 kg-m)
7. Bleed system.
8. Inspect system for any leaks.