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Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
dle but only remove one. Swing the caliper free from the
rotor.
Note the orientation of the brake pads for reassembly pur-
pose. Push out the two guide/retainer pins from the cali-
per and remove pads.
Install new set of pads:
Position the new pads in the same orientation as the ones
removed. If the pads have been correctly positioned, the
guide/retainer pins will easily engage. Reinsert the guide/
retainer pins, making sure they are correctly seated in the
grooves machined in the caliper casting.
Gently push the pads away from each other to provide
adequate clearance with the rotor and then swing the
entire caliper and pad assembly back over the rotor.
Secure the caliper to the spindle and tighten both bolts to
25 - 30 ft. lbs (33 - 40 Nm) torque.
Rotor Replacement
NOTICE: The rotor (disc brake hub) is not designed
to be trued ("turned").
If the rotor has deep grooves or gouges, it must be
replaced.
If the pad contact area has worn the rotor to 120" (3
mm) or less, the rotor must be replaced.
Swing the caliper and pads out of the way to gain access
to the rotor. See Brake Pad Replacement on page 64.
The disc hub (rotor) can be serviced in the same manner
as the hub on non-front disc brake equipped vehicles.
Refer FRONT SUSPENSION AND STEERING section
for:
•
Hub Replacement
•
Wheel Bearing and Race Replacement
•
Wheel Bearing Packing
•
Wheel Bearing Adjustment
Spindle Replacement
Refer FRONT SUSPENSION AND STEERING section.
Actuator Linkage Bushings
NOTICE: Removing the front shield may improve
accessibility to brake components. (Refer BODY
section).
Remove cotter pin and washer that secures the lower
actuator pivot to the actuator linkage. Discard cotter pin.
Retain washer for reuse.
Install a new nylon bushing, flange down, to the lower
actuator pivot.
653045
FRONT HYDRAULIC BRAKES
Reconnect the actuator linkage using washer and a new
cotter pin.
Actuator Pivot Bushings
NOTICE: Removing the front shield may improve
accessibility to brake components. (Refer to the
BODY section).
Both the upper and lower actuator pivots contain an ace-
tal flanged bushing at both ends of the actuator and are
unlikely to require replacement.
The upper actuator pivot also is fitted with a nylon bush-
ing between it and the brake cylinder clevis. To replace
any of these bushings, the actuator linkage must be
removed from the lower actuator pivot and the linkage
rod. See Actuator Linkage Bushings on page 65.
Remove the cotter pin and clevis pin securing the upper
actuator pivot and master cylinder clevis.
Remove the lock nut and shoulder bolt to remove the
pivot components.
Bushings may now be removed and replaced with new
ones. Be sure to replace the nylon bushing with the
flange facing upward.
Reassemble using new cotter pins.
Tighten lock nut to 5 - 10 ft. lbs (7 - 13 Nm) torque.
BLEEDING BRAKES
Tool List
Hose .........................................................................AR
Clean Container...........................................................1
Brake Fluid, DOT 3 ...................................................AR
Box End Wrench, 1/4" .................................................1
General Information about Bleeding Brakes
The hydraulic brake system must be free of air to operate
properly. Air can enter the system when hydraulic parts
are disconnected for servicing or replacement, or when
the fluid level in the master cylinder reservoir is low. Air in
the system gives the brake pedal a spongy feeling when
pressed.
NOTICE: An assistant is required to perform this
procedure.
Use a clean cloth to wipe off the master cylinder reservoir
and wheel cylinder bleeder valves. Clean each fitting
before opening to prevent contaminating the system.
Open the master cylinder reservoir and top off with stan-
dard automotive DOT 3 brake fluid.
Repair and Service Manual
B
Quantity
65
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