Astro, Safari 1997-2005

Brake Pads

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder.
  4.  
  5. Remove wheels and tires.
  6.  
  7. Place a C-clamp around the outer pad and caliper; tighten the C-clamp until the piston is fully compressed in the caliper. Remove top caliper retainer, and rotate caliper away from rotor.
  8.  
  9. Remove inboard pad and retaining spring from the caliper.
  10.  
  11. Remove outboard pad from the caliper.
  12.  

To install:

  1. Clean and lubricate the sleeves and bushing with silicone lubricant.
  2.  
  3. Install sleeves and bushings in the caliper.
  4.  
  5. Clip the retaining spring onto the inboard pad.
  6.  
  7. Install inboard pad in the caliper.
  8.  
  9. Install outboard pad into the caliper.
  10.  
  11. Install caliper in position over the rotor.
  12.  
  13. Install mounting bolts.
  14.  
  15. Install wheel and tire assemblies.
  16.  
  17. Refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.
  18.  

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove wheels
  6.  
  7. Place a C-clamp around the outer pad and caliper; tighten the C-clamp until the piston is fully compressed in the caliper. Remove top caliper retainer, and rotate caliper away from rotor.
  8.  
  9. Remove the inboard pad and retaining spring from the caliper.
  10.  
  11. Remove the outboard pad from the caliper.
  12.  

To install:

  1. Clean and lubricate the sleeves and bushing with silicone lubricant and install them in the caliper.
  2.  
  3. Clip the retaining spring onto the inboard pad and install the pad in the caliper.
  4.  
  5. Install the outboard pad into the caliper.
  6.  
  7. Install the caliper in position over the rotor and install the mounting bolts.
  8.  
  9. Install the wheel and tire assemblies.
  10.  
  11. Lower the vehicle, refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.
  12.  

 
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