Front
Front Brake Pad Inspection and ReplacementCAUTION:
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
^ Avoid breathing dust particles.
^ Never use an air hose or brush to clean brake assemblies. Use an OSHA approved vacuum cleaner.
Inspection
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheels.
3. Remove the brake pads.
4. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include the brake pad backing plate (A) thickness.
5. If the brake pad thickness is less than the service limit, replace the front brake pads as a set.
6. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
Replacement
1. Remove some brake fluid from the master cylinder.
2. Raise the front of the vehicle, and support it with safety stands in the proper locations.
3. Remove the front wheels.
4. Remove the flange bolt (A) while holding the caliper pin (B) with a wrench and being careful not to damage the pin boot, and pivot the caliper (C) up out of the way. Check the brake hose and pin boots for damage and deterioration.
5. Remove the brake pads (A) and the pad shims (B).
6. Remove the pad retainers (A).
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed.
8. Inspect the brake disc, and check for damage and cracks.
9. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off of the brake disc and brake pads.
10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the back of the brake pads (B), and the other areas indicated by the arrows. Wipe excess paste off the pad shims and brake pads. Contaminated brake discs or brake pads reduce stopping ability. Keep assembly paste off of the brake discs and brake pads.
11. Install the brake pads and pad shims correctly. Install the brake pads with the wear indicator (C) on the lower inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
12. Push in the piston (A) so the caliper will fit over the brake pads. Check the brake fluid level. The fluid may over flow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
NOTE: Be careful when pressing in the caliper piston; brake fluid might overflow from the master cylinder's reservoir.
13. Pivot the caliper (B) down into position. Install the flange bolt (C), and tighten it to the specified torque while holding the caliper pin (D) with a wrench and being careful not to damage the pin boot.
14. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheels.
15. Add brake fluid as needed.
16. Press the brake pedal several times to make sure the brakes work.
NOTE: Engagement 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.
17. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then check for leaks.