Front

Removal

WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators.
Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area.





1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings.

Loosen the wheel nuts.
1. Remove the center cap.
2. With the weight of the vehicle on the wheels, loosen the wheel nuts.

2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.

3. Remove the wheel and tire assembly.
1. Remove the wheel nuts.
2. Remove the wheel and tire assembly.

4. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets.

Inspect the pads for wear or contamination.





5. CAUTION: When removing the front disc brake caliper, never allow it to hang from a brake hose. Provide a suitable support.

Remove the disc brake caliper.
1. Remove the caliper bolts using a T45 Torx(R).
2. Lift the disc brake caliper off the front disc brake caliper anchor plate.





6. On 4x2 vehicles, measure the brake disc thickness.
^ Install a new brake disc and hub if not within specification.





7. On 4x4 vehicles, measure the brake disc thickness.
^ Install anew brake disc if not within specification.





8. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.





9. Remove the disc brake anti-rattle clips.
1. Remove the pads.
2. Remove the disc brake anti-rattle clips.

Installation





1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the front brake pad lining material. Do not install contaminated pads.

Install the pads.
1. Install the disc brake anti-rattle clips.
2. Install the pads.





2. CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield.

Install the disc brake caliper.
1. Install the disc brake caliper.
2. Install the disc brake caliper bolls.

3. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control.

Clean the wheel hub mounting surface.
4. Install the tire and wheel assembly.
5. Install the center cap.
6. Inspect the brake operation.