Front

Removal

1. Check fluid level in brake master cylinder reservoir. Remove brake fluid until brake master cylinder reservoir is half-full.
2. Raise vehicle on hoist.

3. NOTE: It is not necessary to disconnect hydraulic connections.

Remove wheel and tire. Use care to avoid damage or interference with wheel cylinder bleeder screw during removal.

4. Use a 10 cm (4 inch) C-clamp and wood block 70 mm x 25 mm (2 3/4 x 1 inch) and approximately 19 mm (3/4 inch) thick to seat the caliper piston in its bore. This must be done to provide clearance for the disc brake caliper to fit over the front disc brake rotor during installation.
5. Remove two caliper anchor bracket mounting bolts.






6. Lift disc brake caliper/front disc brake caliper anchor plate away from front disc brake rotor using a rotating motion.

7. Remove outer brake shoe and lining assembly from disc brake caliper assembly by sliding brake shoe and lining in front disc brake caliper anchor plate away from outer leg to disengage it from the front disc brake caliper anchor plate. Remove outer brake shoe and lining.
8. Remove inner brake shoe and lining assembly from disc brake caliper assembly by sliding brake shoe and lining in front disc brake caliper anchor plate away from caliper piston disengaging it from the front disc brake caliper anchor plate. Remove inner brake shoe and lining.
9. Support the disc brake caliper assembly in a manner that will not stretch or damage the front brake hose.
10. Inspect both disc brake rotor braking surfaces. Minor scoring or buildup of brake shoe and lining material does not require machining or replacement of the front disc brake rotor. Hand-sand glaze off both front disc brake rotor braking surfaces using garnet paper 100A (medium grit) or aluminum oxide 150-J (medium grit).

Installation
1. Use a 10 cm (4 inch) C-clamp and wood block 70 mm x 25 mm (2 3/4 x 1 inch) and approximately 19 mm (3/4 inch) thick to seat caliper piston in its bore. This must be done to provide clearance for disc brake caliper assembly to fit over front disc brake rotor during installation.

2. NOTE: Disc brake caliper has provision to allow brake shoe hold-down spring to be installed only one way. Right and left brake shoe hold-down springs are identical but installed in opposite directions.

Clean front disc brake caliper legs and brake shoes and linings as necessary. Make sure brake shoe hold-down spring is seated in caliper lining inspection opening. Brake shoe hold-down spring must be installed from the lining side.

3. NOTE: Police applications Brake shoes and linings are interchangeable.

Brake shoes and linings are marked LH and RH. A directional arrow is painted on the lower edge of each brake shoe and lining. This arrow, when in correct position, will point toward front of vehicle.

4. Peel protective paper from insulator on the brake shoe and lining assembly. The insulator is black in color when paper is removed. This pressure-sensitive adhesive insulator functions to reduce noise. Care should be exercised to avoid contamination of the adhesive surface prior to installation of the brake shoes and linings.
5. Engage the brake shoe and lining in the front disc brake caliper anchor plate by first engaging the side opposite the brake shoe hold-down spring. Press the other end of the brake shoe and lining to compress the brake shoe hold-down spring and engage the brake shoe and lining in the front disc brake caliper anchor plate . Both inner and outer brake shoes and linings are installed in the same manner.

6. Inspect disc brake caliper/front disc brake caliper anchor plate assembly to make sure brake shoes and linings are properly installed and that arrows are pointing toward front of vehicle, and that brake shoe and lining faces front disc brake rotor.

7. NOTE: It is important to use correct bolt (M14 x 2.0 x 28 mm long).

Position disc brake caliper/front disc brake caliper anchor plate assembly over front disc brake rotor. Install two disc brake caliper anchor bracket mounting bolts. Tighten to 170-230 Nm (125-170 lb-ft).

8. Install wheel and tire assembly. Tighten lug nuts to 115-142 Nm (85-105 lb-ft).
9. Lower vehicle.
10. Pump brake pedal several times to position brake shoes and linings. Refill brake master cylinder as necessary.
11. Road test vehicle.