Front Brake; Service Limits; Inspection; Replace Pads - Taylor-Dunn B5-540-48XL Service And Replacement Parts Manual

B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48

FRONT BRAKE

WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.

Service Limits

Refer to the table at the end of this section

Inspection

Note: Service Limits are listed in a table at the end of
this section.
1: Raise the front of the vehicle and support with jack
stands.
2: Remove the front wheels.
3: Measure the brake lining (not including the metal
backing plate) of each pad at it's thinnest point. If
any one of the brake pads are equal to or less that the service limit then all pads should be replaced.
4: Measure the rotor thickness in three places. If the rotor thickness is less than the service limit then the rotor
must be replaced.
5: Measure the rotor runout. If the runout exceeds the service limit, then the rotor must be resurfaced. After
resurfacing the rotor, measure the rotor thickness. If the rotor thickness is less than the service limit, then the
rotor must be replaced.
6: Lower the vehicle.
7: Reconnect the battery, remove the blocks from behind the wheels and test drive.

Replace Pads

Note: Installing new brake pads will raise the brake fluid level in the master cylinder.
1: Thoroughly clean the area around the master cylinder cap.
2: Remove fluid from the master cylinder until it is 1/2 full.
3: Raise the front of the vehicle and support with jack stands.
4: Remove the tire/wheel assembly. Refer to Tires and Wheels section for information on removing the tire and
wheel assembly.
Note: Refer to the illustration for the following steps.
5: Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8).
6: Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings.
7: Inspect the brake rotor. See Inspect the Service Brakes section for information regarding inspecting the
brake rotor.
8: Inspect the spacers (7) and replace if any wear or damage is found.
9: Install new spacer bushings in the mounting bracket.
10: Install new brake pads and assemble the caliper in reverse order. Torque the brake body per specification at
the end of this section.
11: Install the tire/wheel assembly onto the hub and lower the vehicle to the ground.
12: Fill the master cylinder to the proper level. Refer to Check Master Cylinder Fluid section for information on
the proper master cylinder fluid level.
13: Reconnect the battery, remove the blocks from behind the wheels and test drive.
MB-440-06
Brakes
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