Special tool
Dial indicator stand 100-053 (LRT-99-503) |
CAUTION: Brake rotors should be rebuilt in pairs unless one rotor requires replacement in less than 1,000 miles (1,500 km).
1. Remove the brake hose bracket from the knuckle. Unscrew the bolt.
2.
CAUTION: The brake pad wear indicator sensor is very easy to damage. Do not use a lever to remove the sensor. The operation must be performed manually.
Left side only: Disconnect the brake pad wear indicator sensor.
3. Remove the lower brake caliper bolt.
4. Remove the upper brake caliper bolt.
5. Move the brake caliper housing to the side and tie it down.
6. Remove the brake caliper support plate. Remove the two bolts.
7. Measure the brake disc thickness in four places. Restore the brake disc if its thickness is less than the maximum permissible thickness or if the maximum permissible thickness deviation is exceeded. Brake disc thickness: NEW = 30 mm, maximum permissible thickness = 27 mm.
8. Using the special tool, install a dial indicator on the lower support of the brake caliper. Position the plunger of the dial indicator so that it is 5 mm from the outer edge of the brake disc.
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9. Tighten the wheel nuts.
- There should be spacer rings under the wheel nuts.
- Tighten the wheel nuts (tightening torque 140 Nm).
10. Rotate the brake disc one revolution to measure the brake disc runout. The brake disc runout should not exceed 0.05 mm.
11. If the brake disc runout is outside the specified limits Remove the brake disc.
12. Make sure the contact surfaces of the brake disc and wheel hub are clean.
13. Install the brake disc. Tighten the Torx head screw. (tightening torque 35 Nm).
14. Tighten the wheel nuts.
- There should be spacer rings under the wheel nuts.
- Tighten the wheel nuts (tightening torque 140 Nm).
15. Rotate the brake disc one revolution to measure the brake disc runout. The brake disc runout should not exceed 0.05 mm.
16. If the brake disc runout is still outside the specified limits, install a new brake disc and/or hub.
17. Remove the dial indicator and special tool.
18.
CAUTION: Do not use compressed air to clean brake components. Dust from friction materials is harmful if inhaled.
Clean the brake caliper body and backing plate with a special brake cleaner.
19. Install the anchor plate. Tighten the bolts. (tightening torque 275 Nm).
20. Install the brake caliper housing and insert the upper bolt. Tighten the bolt. (tightening torque 32 Nm).
21. Install the brake pads. Install two clamps.
22. Turn the brake caliper down. Tighten the bolt. (tightening torque 32 Nm).
23. Connect the brake pad wear indicator sensor.
24. Install the brake hose bracket onto the knuckle. Tighten the bolt. (tightening torque 22 Nm).
25. Press the brake pedal, check the level of working fluid in the brake hydraulic reservoir and top up if necessary.
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