Rear

WARNING:
- Never use an air hose or dry brush to clean brake assemblies.
- Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.
- Block the front wheels before jacking up the rear of the vehicle.

1. Block the front wheels, loosen the rear wheel nuts slightly, support the rear of vehicle on safety stands, then remove the rear wheels.
2. Release the parking brake.





3. Remove the rear caliper protector.





4. Hold the caliper pins with a thin, open-end wrench, and remove the two caliper bolts and the caliper from the bracket.

CAUTION:
- Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
- Support the caliper with a piece of wire so that it does not hang from the brake hose.





5. Remove the pad shims and brake pads.

Brake Pad Thickness:

6. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include the pad backing plate thickness.

Brake Pad Thickness:
Standard: 8.3 - 9.0 mm (0.33 - 0.35 inch)
Service Limit: 1.6 mm (0.06 inch)

7. If the pad thickness is less than the service limit, replace the pads and shims together as a set.
8. Remove the pad retainers.
9. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
10. Check the brake disc for damage and cracks.





11. Make sure that the pad retainers are installed in the correct positions.





12. Apply Molykote M77 grease to both sides of the shims. Wipe excess grease off the shims.
13. Install the brake pads and pad shims on the caliper bracket. Install the pad with the wear indicator on the inside.

WARNING:
- When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency.
- Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.





14. Rotate the caliper piston clockwise into the cylinder, then align the cutout in the piston with the tab on the inner pad by turning the piston back.

CAUTION: Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it sits properly.

15. Install the brake caliper.
16. Install and tighten the caliper bolts while holding the caliper pins with a thin, open-end wrench.





17. Install the rear caliper Protector.
18. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
19. Depress the brake pedal several times to make sure the brakes work, then road-test.

NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.