Overhaul
Front Disc Brake (Part 1 Of 2):
Front Disc Brake (Part 2 Of 2):
REMOVAL
1. Raise vehicle and support.
2. Remove wheel and tire assembly. Do not damage brake caliper bleeder screw fitting during removal.
3. Disconnect front brake hose from front disc brake caliper. Remove hollow retaining bolt that connects hose fitting to front disc brake caliper. Remove hose assembly from front disc brake caliper and plug hose. Discard copper washer
4. Remove two rear brake pin retainers. Lift disc brake caliper off front disc brake rotor using rotating motion.
NOTE:If rotor is to be removed, mark rotor and one stud with touch-up paint to ensure proper alignment.
DISASSEMBLY
CAUTION: Do not use a screwdriver or any similar tool to pry caliper piston out of bore. It will result in damage to caliper piston. Cushion caliper piston's impact against disc brake caliper when blowing it out of bore by placing a wooden block or shop towels between caliper piston and caliper bridge. Use care because the caliper piston can develop considerable force from pressure buildup.
^ Apply air pressure to the fluid port in the disc brake caliper with a rubber-tipped air gun to remove caliper piston. Replace caliper if caliper is seized and cannot be forced from the disc brake caliper.
CLEANING & INSPECTION
^ Visually check disc brake caliper. If front disc brake caliper housing is leaking, disc brake caliper should be replaced
^ If a seal is leaking, disc brake caliper must be disassembled and new seals and dust boot installed.
^ If a caliper piston is seized in the bore, the disc brake caliper must be replaced.
^ Clean all metal parts with isopropyl alcohol. Then, clean out and dry grooves and passageways with compressed air. Make sure caliper bore and component parts are thoroughly clean.
^ Check caliper bore and piston for damage of excessive wear. Replace disc brake caliper if piston or bore is pitted, scored, corroded or the plating is worn off piston.
ASSEMBLY
1. Clean foreign material from caliper piston and lubricate with brake fluid
2. Install new seal into caliper bore and dust boot onto piston. Insert piston into disc brake caliper.
3. Start caliper piston into disc brake caliper housing by hand for correct alignment.
Retracting Caliper:
4. Seat caliper piston fully into bore, using a wood block or other flat stock, like an old brake shoe lining assembly, between a C-clamp and caliper piston. Do not apply C-clamp directly to caliper piston surface. This can result in damage to caliper piston. Be sure caliper piston is not cocked.
5. Ensure dust boot is tight in boot groove on caliper piston and in disc brake caliper.
INSTALLATION
NOTE:Clean all dirt or foreign material from mating surfaces of caliper locating pins and caliper housing ears. Dirt can cause caliper locating pins to be crooked after rear brake pin retainers are torqued, preventing disc brake caliper from sliding properly.
1. Make sure inner and outer shoes are properly positioned in front disc brake caliper anchor plate. Make sure front wheel disc brake shoe insulators are attached to the brake shoe plate. Make sure lining material is facing front disc brake rotor.
2. Install disc brake caliper over front disc brake rotor and brake shoes and linings.
3. Install rear brake pin retainer through front disc brake caliper holes into disc brake caliper locating pins and hand start.
NOTE: To make sure correct disc brake caliper is installed on correct side of vehicle. The bleeder screw should be on top of disc brake caliper when assembled on vehicle.
4. Tighten two brake pin retainers to 31-38 Nm (23-28 ft. lbs.).
5. Remove plug and install front brake hose on disc brake caliper with a new copper washer on each side of fitting outlet. Insert retaining bolt through washers and fitting. Tighten to 41-54 Nm (31-39 ft. lbs.).
NOTE: Always re-install rubber bleed screw cap after bleeding.
6. Bleed the serviced disc brake caliper.
MANUAL BLEEDING
NOTE: When the brake system is emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the system by performing the Master Cylinder Bleeding procedure. Service and Repair
1. To bleed brake system, position suitable box wrench on bleeder fitting. Attach rubber drain tube to bleeder fitting. The end of tube should fit snugly around bleeder fitting.
2. Submerge free end of the tube in container partially filled with clean brake fluid and loosen bleeder fitting approximately three-quarters of a turn.
3. Have assistant push brake pedal down slowly through its full travel. Close bleeder fitting and return the brake pedal to full release position.
4. Repeat Steps 2 and 3 until air bubbles cease to appear at submerged end of bleeder tube.
5. When fluid is completely free of air bubbles, secure bleeder fitting and remove bleeder tube.
6. Refill brake master cylinder reservoir after each system is bled and install master cylinder reservoir cap and gasket. Make sure diaphragm type gasket is properly positioned in master cylinder reservoir cap. When bleeding operation is completed, fluid level should be between MAX line and 4.0 mm (0.16 inch) below.
7. If necessary, Repeat this procedure for the opposite front caliper.
8. If necessary, Repeat this procedure for the opposite diagonal system.
9. After disc brake service, make sure disc brake pistons are returned to their normal positions and shoe and lining assemblies are properly seated. This is accomplished by applying brake pedal several times until normal pedal travel is established.
10. Check pedal feel. If brake pedal feels spongy repeat bleed procedure,perform additional bleeding procedures, Refer to Brakes - Service and Repair, or perform diagnosis procedure. Service and Repair Symptom Related Diagnostic Procedures
11. Fill brake master cylinder with specified brake fluid to between MAX line and 4 mm (0.16 inch) below MAX line on reservoir. Use High Performance DOT-3 Motor Vehicle Brake Fluid .
CAUTION: Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
12. Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm (85-104 ft.lbs) using Accutorq Lug Nut Socket or equivalent on a 1/2 inch air impact wrench, or use a torque wrench.
13. Lower vehicle.
14. Road test vehicle.