Front Disc Brake Pads Replacement (2500 Series)

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

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

2. Slowly tighten the C-clamps until the caliper pistons a pushed completely into the caliper bores.

3. Remove the C-clamps from the caliper.




7. Remove the brake caliper guide pin bolts.

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.

Caution: Refer to Brake Caliper Caution Brake Caliper Caution.

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

9. Remove the brake pads from the brake caliper bracket.

10. Note the orientation of the brake pad wear sensor (if equipped) for installation.

Note: Do not reuse the brake pad retaining springs.

11. Remove and discard the brake pad retaining springs.

12. 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 disc brake pads to the brake caliper bracket, positioning the brake pad wear sensor (if equipped) as noted during removal.




3. Install the brake caliper to the caliper bracket.

Caution: Refer to Fastener Caution Fastener Caution.

4. Install the brake caliper guide pin 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 brake pedal is obtained, to properly seat the brake caliper pistons and brake pads.

10. Fill the brake 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 brake pads and discs. Refer to Brake Pad and Rotor Burnishing Procedures.