Front Disc Brake Pads Replacement 2500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

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



6. Compress the brake caliper pistons.

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

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

6.3.	Remove the C-clamps from the caliper.




7. Remove the brake caliper guide pin bolts.

Caution: Refer to Brake Caliper Caution in the Preface section.

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.

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.

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 in the Preface section.

4. Install the brake caliper guide pin bolts and tighten to 108 N·m (80 lb ft).
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
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.
11. Burnish the brake pads and discs. Refer to Brake Pad and Rotor Burnishing.

Front Disc Brake Pads Replacement 1500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

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



6. Compress the brake caliper pistons.

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

6.2.	Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores.

6.3.	Remove the C-clamps from the caliper.

Note: 

•	DO NOT use any air tools to remove the guide pin bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.




7. Using an open end wrench to hold the guide pin, loosen the brake caliper guide pin bolt.



8. Remove the lower brake caliper guide pin bolt (1).

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.

Note: DO NOT disconnect the flexible brake hose from the brake caliper.

9. Rotate the brake caliper (2) upward until it rests on the brake caliper mounting bracket and support with heavy mechanics wire or equivalent.

Note: If installing the original brake pads, mark the position of the inner and outer brake pads for proper installation.

10. Remove the brake pads (3).

Note: 

•	If installing the original brake pads and shims, mark the position of the shims for the proper installation.

•	DO NOT reuse the brake pad shims with new brake pads. Replace with NEW only.

11. Remove the brake pad shims (4) from the mounting bracket (5).

Note: Use care when cleaning the brake caliper pistons to avoid damaging the piston dust seals.

12. Thoroughly clean the brake caliper piston faces and caliper to brake pad contact surfaces of all disc brake pad insulator adhesive residue with denatured alcohol and allow to dry.

1. Install the shims (4) to the mounting bracket.

•	Install the NEW shims if replacing the brake pads.

•	Install the original shims in their original position if installing the original brake pads.

2. If installing new brake pads, remove the adhesive backing paper from the brake pad insulator.

Note: If installing the original brake pads, position the brake pads as marked during the removal procedure.

3. Install the brake pads (3).
4. Rotate the brake caliper (2)  into the proper position on the mounting bracket (5).

Caution: Refer to Fastener Caution in the Preface section.





Note: 

•	DO NOT use any air tools to remove or tighten the guide pin bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the caliper guide pin in line with the caliper while removing or installing the caliper. DO NOT allow the wrench to come in contact with the brake caliper. Allowing the wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

5. Use an open end wrench to hold the caliper guide pin while tightening the brake caliper guide pin bolt to 100 N·m (74 lb ft).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
7. Lower the vehicle.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained to properly seat the brake caliper pistons and pads.
11. Firmly apply and maintain pressure on the brake pedal for 30 seconds to seat the brake pad insulators to the brake caliper pistons and caliper housing.
12. Fill the brake master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.
13. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing.