Special tool
Stand for dial indicator 100-053 (LRT-99-503) |
WARNING: Brake discs should be rebuilt in pairs unless one of the discs requires a new one in less than 1000 miles (1500 km).
1. Remove the brake hose bracket from the knuckle. Turn out a bolt.
2.
CAUTION: The brake pad wear indicator sensor can be damaged very easily. Do not use the lever to remove the sensor. The operation is performed only 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 aside and tie it down.
6. Remove the brake caliper base plate. Turn out two bolts.
7. Measure the thickness of the brake disc in four places. Rebuild the brake disc if its thickness is less than the maximum allowable thickness or if the maximum allowable thickness deviation is exceeded. Brake Disc Thickness: NEW = 30mm, Max Thickness = 27mm.
8. Using the special tool, install a dial indicator on the lower support of the brake caliper. Position the dial indicator plunger so that it is 5 mm from the outer edge of the brake disc.
9. Tighten the wheel nuts.
- There should be spacer rings under the wheel nuts.
- Tighten wheel nuts (tightening torque 140 Nm).
10. Rotate the brake disc one turn to measure the runout of the brake disc. The runout of the brake disc must not exceed 0.05 mm.
11. If the brake disc runout is out of range 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 Torx Head Screw (tightening torque 35 Nm).
14. Tighten the wheel nuts.
- There should be spacer rings under the wheel nuts.
- Tighten wheel nuts (tightening torque 140 Nm).
15. Rotate the brake disc one turn to measure the runout of the brake disc. The runout of the brake disc should not exceed 0.05 mm.
16. If brake disc runout is still out of range, 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 parts. Dust from friction materials is harmful when it enters the lungs.
Clean the brake caliper housing and base plate with special brake cleaner.
19. Install the anchor plate. Tighten the bolts (tightening torque 275 Nm).
20. Install the brake caliper housing and insert the top bolt. tighten bolt (tightening torque 32 Nm).
21. Install the brake pads. Install two clamps.
22. Turn the brake caliper down. tighten bolt (tightening torque 32 Nm).
23. Connect the brake pad wear indicator sensor.
24. Install the brake hose bracket to the knuckle. tighten bolt (tightening torque 22 Nm).
25. Depress the brake pedal, check the fluid level in the brake fluid reservoir and top up if necessary.
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