Rear Disc Brake Pads Replacement (2500 Series)

Rear Disc Brake Pads Replacement (2500 Series)

Warning: Refer to Brake Dust Warning Brake Dust Warning.


Note: Always replace disc brake pads in axle sets.

Removal Procedure




1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.

3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.

4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Removal and Replacement.

6. Compress the brake caliper pistons.

1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad.

2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.

3. Remove the C-clamp from the caliper.

Caution:
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.




7. Remove the brake caliper guide pin bolts.

8. Remove the caliper from the caliper bracket and support with heavy mechanics wire or equivalent.




9. Remove the brake pads from the caliper bracket.

Note: Do not reuse the brake pad retaining springs.

10. Remove and discard the brake pad retaining springs.

11. Inspect the brake caliper. Refer to Brake Caliper Inspection Testing and Inspection.

Installation Procedure




1. Install NEW brake pad retaining springs to the caliper bracket.

2. Install the brake pads to the caliper bracket.




3. Install the caliper to the caliper bracket.

Caution: Refer to Fastener Caution Fastener Caution.

4. Install the brake caliper bolts and tighten to 108 Nm (80 lb ft).

5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Removal and Replacement.

6. Lower the vehicle.

7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

8. Slowly release the brake pedal.

9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained, to properly seat the brake caliper pistons and brake pads.

10. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling.

11. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing Procedures.