Brake Rotor/Disc: Service and Repair

REMOVAL AND INSTALLATION





1. Remove free-running hub assembly.
2. Remove brake caliper assembly without disconnecting hydraulic line.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.





3. Remove lock washer. - 4WD -





4. Remove wheel bearing lock nut.
2WD: With suitable tool
4WD: With Tool





5. Remove wheel hub and wheel bearing.
Be careful not to drop outer bearing.

6. After installing wheel hub and wheel bearing, adjust wheel bearing preload.

DISASSEMBLY





- Remove bearing outer races with suitable brass bar.

INSPECTION
Thoroughly clean wheel bearings and wheel hub.

Wheel Bearings
- Make sure wheel bearings roll freely and are free from noise, cracks, pitting and wear.

Wheel Hub
- Check wheel hub for cracks by using a magnetic exploration or dyeing test.

ASSEMBLY





1. Install bearing outer race with Tool until it seats in hub.





2. Install the sensor rotor using suitable drift and press. (Models with ABS) Always replace sensor rotor with new one. Pay attention to the direction of front sensor rotor as shown in figure.





3. Pack multipurpose grease in wheel hub and hub cap.





4. Apply multipurpose grease to each bearing cone.
5. Pack grease seal lip with multipurpose grease, then install it into wheel hub with suitable drift.