Brake Shoe and Lining

Dual Piston Caliper

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 or wheel cylinder bleeder screw.

   NOTE: It is not necessary to disconnect hydraulic connections.

4. Remove circlip washer and disc brake caliper locating pin (2B296).

5. Remove front disc brake caliper (2B121) from front disc brake rotor (1125) and mounting bracket. Support front disc brake caliper in a manner that will not stretch or damage front brake hose (2078) .

6. Remove brake shoes and linings (2001).

   NOTE: Removed brake shoes and linings as right and left for assistance in identifying replacement parts. Clean all residue from mounting bracket and caliper brake shoe and lining contact area.

7. Inspect both rotor braking surfaces minor scratches 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 100 A (medium-grit) or aluminum oxide 150 J (medium).

8. Inspect piston boots and caliper pin boots from damaged and repair as necessary.

Installation

NOTE: There are four unique brake shoes and linings in a brake shoe and lining kit. Outboard brake shoe and lining with insulator is installed in the front disc brake caliper , the inboard brake shoe and lining is pressed into the wheel cylinder pistons (2196) . Biasing springs will prevent the wrong brake shoe and lining from assembling into the mounting bracket. Compare removed brake shoes and linings to the brake shoes and linings supplied in kit to identify parts as right or left.

1. Clean all residue from the mounting bracket and caliper shoe and lining contact area.

2. Peel protective paper from insulator on the brake shoe and lining . The insulator is black in color when the paper has been removed.

3. Install brake shoes and linings . Make sure that brake shoes and linings are free of grease and oil, push brake shoes and linings in firmly until flush and fully seated in front disc brake caliper bottom wheel cylinder pistons . Use a 10cm (4-inch) C-clamp and wood block 70mm x 25mm (2.75 x 1 inch) and approximately 19mm (3/4 inch) thick. This must be done to provide clearance for the front disc brake caliper to fit over front disc brake rotor during installation. 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 .

4. Install front disc brake caliper over front disc brake rotor and onto mounting bracket. Make sure that the guiding surfaces of brake shoe and lining and mounting bracket are seating correctly.

5. Install disc brake caliper locating pin and circlip by pressing front disc brake caliper down to compress bias spring and sliding disc brake caliper locating pin into position and securing wi
   
   
   
   
   

   Item	Part Number	Description
   1	2001	Inboard Brake Shoe and Lining
   2	2001	Outboard Brake Shoe and Lining With Insulator
   3	2B119	Front Disc Brake Caliper