Front Disc Brake Pads Replacement 1500 Series

Caution: Refer to Brake Dust Caution 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.

Important: 

•	DO NOT use any air tools to remove or install 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 lower brake caliper guide pin bolt.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.




8. Rotate the caliper upwards.
9. Remove the brake pads from the caliper bracket.



10. Remove and discard the anti-rattle clips.

1. Install NEW anti-rattle clips to the caliper bracket.



2. Install the brake pads to the caliper bracket.

The inner pad has one wear indicator, the outer pad has none.

3. Rotate the caliper back down and into place.

Notice: Refer to Fastener Notice in the Preface section.





Important: 

•	DO NOT use any air tools to remove or install 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.

4. Using an open end wrench to hold the guide pin, install the lower brake caliper guide pin bolt.

Tighten
Tighten the bolt to 100 N·m (74 lb ft).




5. Ensure the brake caliper guide pin seal (4) is fully seated in the groove of the brake caliper guide pin (5), and the guide pin moves smoothly in the bore of the brake caliper bracket (3).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
7. Remove the safety stands.
8. Lower the vehicle.
9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
10. Slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained. This will properly seat the brake caliper pistons and pads.
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 .

Front Disc Brake Pads Replacement 25/3500 Series

Caution: Refer to Brake Dust Caution 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. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
5. Compress the brake caliper pistons.

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

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

5.3.	Remove the C-clamps from the caliper.




6. Remove the brake caliper bolts.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

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

7. Remove the caliper from the caliper bracket.

Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper.




8. Remove the brake pads from the caliper bracket.
9. Remove and discard the anti-rattle clips.
10. Inspect the caliper and caliper bracket. Refer to Brake Caliper Inspection .

1. Install NEW anti-rattle clips to the caliper bracket.
2. Install the disc brake pads.

•	2500 Series--Inner and outer pad with wear sensor leading

•	3500 Series--Install the inner and outer pads.




3. Install the caliper to the caliper bracket.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the brake caliper bolts.

Tighten
Tighten the bolts to 108 N·m (80 lb ft).

5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
6. Remove the safety stands.
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. This will properly seat the brake caliper pistons and pads.
11. Fill the brake master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling .
12. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .