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

Brake Disc (Rotor)

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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. Raise the vehicle on a hoist.
  2.  
  3. Remove the rear wheel and the tire assembly.
  4.  
  5. Remove the rear brake pads.
  6.  
  7. Remove the brake pipe to the rear axle control arm bracket.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  8.  
  9. Remove the brake caliper-to-rear axle control arm bolts.
  10.  
  11. Carefully remove the brake caliper bending at the flexible brake hose only.
  12.  
  13. Using mechanics wire, attach the caliper to the rear spring.
  14.  
  15. Remove the rotor retaining screw.
  16.  
  17. Remove the rotor from the vehicle.
  18.  

To install:

  1. Position the rotor onto the hub.
  2.  
  3. Install the rotor retaining screw, and tighten the brake rotor retaining fastener to 35 inch lbs.(4 Nm).
  4.  
  5. Clean the caliper support bracket fasteners thoroughly with brake and choke cleaner P/N 21007432 or equivalent.
    NOTE
    If Loctite® 272 Threadlocker or equivalent is not available, new caliper support bracket fasteners must be used.

  6.  
  7. Apply Loctite® 272 Threadlocker or equivalent to the caliper support bracket fasteners.
  8.  
  9. Install the caliper onto the rear axle control arm and tighten the fasteners, and tighten the rear caliper-to-rear axle control arm to 59 ft. lbs. (80 Nm).
  10.  
  11. Install the brake pipe bracket to the rear axle control arm, and tighten the brake pipe bracket-to-rear axle control arm to 71 lb in (8 Nm).
  12.  
  13. Install the brake pads.
  14.  
  15. Bleed the brakes.
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Lower the vehicle from the hoist.
  20.  


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. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 0.039 inch (1 mm) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  6.  
  7. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
  8.  
  9. Remove the C-clamp from the caliper.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.


    NOTE
    Do NOT disconnect the hydraulic brake flexible hose from the caliper.

  10.  
  11. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose.
  12.  
  13. Matchmark the position of the brake rotor to the wheel studs.
  14.  
  15. Remove the brake rotor.
  16.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the disc brake rotor


NOTE
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Using the J42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  8.  
  9. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes.
  10.  
  11. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications.
  12.  
  13. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors.
  20.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 0.039 inch (1 mm) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  6.  
  7. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
  8.  
  9. Remove the C-clamp from the caliper.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.


    NOTE
    Do NOT disconnect the hydraulic brake flexible hose from the caliper.

  10.  
  11. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose.
  12.  
  13. Matchmark the position of the brake rotor to the wheel studs.
  14.  
  15. Remove the brake rotor.
  16.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the disc brake rotor


NOTE
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Using the J42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  8.  
  9. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes.
  10.  
  11. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications.
  12.  
  13. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors.
  20.  

 
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