Removal & Installation
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.
- Using a syringe, siphon brake fluid from the reservoir, leaving reservoir approximately 1 / 2 full.
- Raise and properly support the vehicle.
- Remove the wheel assemblies.
- Remove the lower pin bolt from the brake caliper.
- Swivel the caliper up and away from the torque member. Tie the caliper to a suspension member so that it is out of the way.
- Lift the 2 brake pads out of the torque member.
- Remove the inner and outer shims. Remove the 2 pad retainers if they are not attached to the pads.
- Check the pad thickness and replace the pads if they are less than 0.079 in. (2mm) thick.
- Install the inner and outer shims into the torque member.
- Install a pad retainer to the bottom of each pad.
- Install the pads into the torque member.
- Use a C-clamp or hammer handle and press the caliper piston(s) back into the housing.
- Untie the caliper and swivel it back into position over the torque plate so that the dust boot is not pinched. Install the pin bolt and torque it to 16-23 ft. lbs. (22-31 Nm) for 1996-01 models; 24-31 ft. lbs. (32-42 Nm) for 2002-04 models.
- Check the condition of the pin boot. Gently pull on it to expel any trapped air.
- Install the wheel and lower the vehicle.
- Pump the brakes until the pedal is firm and check the level of brake fluid. Road-test the vehicle.