Brake Shoe and Lining

Single Piston Calipers

Removal

1. Remove master cylinder cap and check fluid level in reservoir. Remove brake fluid until brake master cylinder reservoir (2K478) is half full. Discard removed fluid.

2. Raise vehicle on hoist. Refer to Section 00-02.

3. Remove wheel and tire assembly from rotor mounting face. Use care to avoid damage or interference with front disc brake rotor shield (2K005) or wheel cylinder bleeder screw (2208) .

   NOTE: It is not necessary to disconnect hydraulic connections.

4. Remove anchor plate mounting bolts.
   
   
   
   

5. Lift front disc brake caliper (2B121) /anchor plate away from front disc brake rotor (1125) using rotating motion.

6. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper assembly by sliding brake shoe and lining in anchor away from outer leg to disengage from anchor plate. Remove outer brake shoe and lining .

7. Remove inner brake shoe and lining assembly by sliding brake shoe and lining in anchor away from wheel cylinder piston (2196) disengaging it from the anchor plate. Remove inner brake shoe and lining .

8. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor . Hand-sand glaze from both rotor braking surfaces using garnet paper 100A (medium-grit) or aluminum oxide 150-J (medium).

9. Inspect piston boot and caliper pin boots for damage and repair as necessary.

10. Support the front disc brake caliper assembly in a manner that will not stretch or damage the front brake hose (2078) .

Installation

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

   NOTE: Front disc brake rotor casting has provision to allow spring to be installed only one way. Right and left hand springs are identical but installed in opposite directions.

2. Thoroughly clean any residue from insulator from front disc brake caliper and brake shoe and lining abutments as necessary. Make certain anti-rattle spring is seated in brake shoe and lining inspection opening. Spring must be installed from lining side.

3. Peel protective paper from insulator on the brake shoe and lining . The insulator is black in color when the paper has been removed. This pressure sensitive adhesive insulator functions to reduce noise and care should be exercised to avoid contamination on the adhesive surface prior to installing the brake shoe and lining in the front disc brake caliper assembly.

4. Engage the shoe in the anchor by first engaging the side opposite the anti-rattle spring. Depress the other end of brake shoe and lining assembly to compress the anti-rattle spring and engage the shoe in the anchor. Both inner and outer brake shoe and lining are installed in this manner.

5. Inspect front disc brake caliper /anchor assembly to assure brake shoe and lining assemblies are properly installed and that lining faces rotor opening.

   NOTE: It is important to use correct bolt (M 12x1.75g property class 10-9, 30-31 long).

6. Install front disc brake caliper/anchor mounting bolts through front wheel spindle (3105) and hand start. Tighten to 130 Nm (95 lb-ft).

7. Install wheel and tire assembly. Tighten wheel hub bolt nuts (1012) to 115-142 Nm (85-105 lb-ft).

8. Lower vehicle.

9. Pump brake pedal prior to moving vehicle to position brake linings. Refill the brake master cylinder (2140) .

10. Road test vehicle.