Brake Pad: Service and Repair

REPLACEMENT
1. Remove front wheel.
Remove the wheel and temporarily fasten the disc with hub nuts.





2. Inspect pad lining thickness.
Check the pad thickness through the caliper inspection hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 inch)





3. Lift up caliper.
a. Remove the installation bolt.
b. Lift up the caliper and suspend it securely.

HINT: Do not disconnect the flexible hose from the caliper.

4. Remove these parts:
- 1 ton: 2 anti-squeal springs.
- 2 brake pads.
- 2 (1 ton) / 4 (0.5 ton) anti-squeal shims.
- 2 pad wear indicator plates.
- 4 pad support plates.

NOTICE: The anti-squeal springs (1 ton) and support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

5. Check disc thickness and runout.
a. Measure disc thickness

Measure Disk Thickness:

Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 inch)
Minimum thickness: 23.0 mm (0.906 inch)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly.
b. Measure disc runout.





Using a dial indicator, measure the disc runout 10 mm (0.39 inch) from the outside edge of the disc.
Maximum disc runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe.

HINT: Before measuring the runout, check that the front hub bearing play is within specification.

6. Install 4 pad support plates.
7. Install new pads.

NOTICE: When replacing worn pads, the anti-squeal shims and wear indicator plates must be replaced together with the pads.





a. Install a pad wear indicator plate to the pad.
b. 1 ton: Install the anti-squeal shim to each pad.
c. 0.5 ton: Install the 4 anti-squeal shims to each pad.





HINT: Apply disc brake grease to both sides of inner anti-squeal shims.





d. Install the 2 pads so that the wear indicator plate is facing underneath.

NOTICE: Do not allow oil or grease on the rubbing face.

8. Install caliper.
a. Draw out a small amount of brake fluid from the reservoir.





b. Press in piston with a hammer handle or equivalent.

HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape.

c. Insert the brake caliper carefully so the boot is not wedged.
d. Install and torque the installation bolts.
Torque:
1 ton: 39 Nm (29 ft. lbs.)
0.5 ton: 36 Nm (27 ft. lbs.)
9. Install front wheel
10. Check that fluid level is at max line.