ION, L-Series, S-Series 1999-2005

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. Remove the front wheels.
  2.  
  3. Remove the caliper lower lock pins.
  4.  
  5. Either pivot the caliper up on the guide pin or remove the upper guide pin and support the caliper from the strut using a coat hanger or length of wire.
  6.  
  7. Remove the 2 brake pads and the pad clips from the caliper support. Discard the old pad clips.
  8.  
  9. Check the caliper pins, pin boots and the piston boot for deterioration or damage.
  10.  

To install:

  1. By hand or using a C-clamp, bottom the piston all the way into the caliper bore.
  2.  
  3. Carefully lift the inner edge of the piston boot by hand to release any trapped air.
  4.  
  5. Install new pad clips into the caliper support.
  6.  
  7. Install the inner and outer brake pads into the support. If installed, remove the temporary support wire from the caliper.
  8.  
  9. Pivot or place the caliper body on the support and upper guide pin into position. Compress the boots by hand as the caliper is positioned onto the support.
  10.  
  11. Lubricate the smooth ends of the removed pin(s) with silicone grease, then install the pin(s) and torque to 27 ft. lbs. (36 Nm). Do not get grease on the pin threads.
  12.  
  13. Install the wheels.
  14.  
  15. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  16.  


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. Use a turkey baster or similar device to remove fluid from the master cylinder until it is about 1 / 2 full.
  4.  
  5. Remove or disconnect the following:

    Front wheel. Hand-tighten the lug nuts on the studs to prevent the rotor from falling off.
     

  6.  
  7. Install a C-clamp over the body of the caliper with the clamp ends against the rear of the caliper body and against the outboard pad. Tighten the clamp until the caliper piston is compressed enough to allow the caliper to be removed.

    Caliper lower bolt
     
    2 brake pads and the pad clips from the caliper support. Discard the old pad clips.
     

  8.  
  9. Check the caliper pins, pin boots and the piston boot for deterioration or damage.
  10.  

To install:

  1. Install or connect the following:

    Brake pads and clips to the caliper bracket
     

  2.  
  3. Lubricate the pin boots and guide pins with silicone grease.
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.



    Pin boots, if removed
     
    Caliper over the brake pads
     
    Caliper lower bolt through the caliper and torque to 27 ft. lbs. (34 Nm)
     



    Wheel
     

  4.  
  5. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  6.  

  1. Remove the front wheels.
  2.  
  3. Remove the caliper lower lock pins.
  4.  
  5. Either pivot the caliper up on the guide pin or remove the upper guide pin and support the caliper from the strut using a coat hanger or length of wire.
  6.  
  7. Remove the 2 brake pads and the pad clips from the caliper support. Discard the old pad clips.
  8.  
  9. Check the caliper pins, pin boots and the piston boot for deterioration or damage.
  10.  

To install:

  1. By hand or using a C-clamp, bottom the piston all the way into the caliper bore.
  2.  
  3. Carefully lift the inner edge of the piston boot by hand to release any trapped air.
  4.  
  5. Install new pad clips into the caliper support.
  6.  
  7. Install the inner and outer brake pads into the support. If installed, remove the temporary support wire from the caliper.
  8.  
  9. Pivot or place the caliper body on the support and upper guide pin into position. Compress the boots by hand as the caliper is positioned onto the support.
  10.  
  11. Lubricate the smooth ends of the removed pin(s) with silicone grease, then install the pin(s) and torque to 27 ft. lbs. (36 Nm). Do not get grease on the pin threads.
  12.  
  13. Install the wheels.
  14.  
  15. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Use a turkey baster or similar device to remove fluid from the master cylinder until it is about 1 / 2 full.
  4.  
  5. Remove or disconnect the following:

    Front wheel. Hand-tighten the lug nuts on the studs to prevent the rotor from falling off.
     

  6.  
  7. Install a C-clamp over the body of the caliper with the clamp ends against the rear of the caliper body and against the outboard pad. Tighten the clamp until the caliper piston is compressed enough to allow the caliper to be removed.

    Caliper lower bolt
     
    2 brake pads and the pad clips from the caliper support. Discard the old pad clips.
     

  8.  
  9. Check the caliper pins, pin boots and the piston boot for deterioration or damage.
  10.  

To install:

  1. Install or connect the following:

    Brake pads and clips to the caliper bracket
     

  2.  
  3. Lubricate the pin boots and guide pins with silicone grease.
    NOTE
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.



    Pin boots, if removed
     
    Caliper over the brake pads
     
    Caliper lower bolt through the caliper and torque to 27 ft. lbs. (34 Nm)
     



    Wheel
     

  4.  
  5. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.
  6.  

 
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