REMOVAL & INSTALLATION
See Figure 1
Always replace all of the brake pads on the same axle at the same time; never replace the pads from one wheel only.
- Siphon approximately 2 / 3 of the fluid out of the master cylinder.
- Loosen all of the front wheel lug nuts 1 / 2 turn.
- Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
- Remove the wheels.
- On Samurai models, use a small prytool to remove the caliper anti-rattle clip from the outboard side of the caliper.
- Remove the two guide pin caps (if equipped), then loosen the two guide pins with a wrench.
- Lift the brake caliper off of the rotor, pads and pad mounting bracket, but do NOT disconnect the brake hose from the caliper.
- Remove the disc pads, and any shims, from the mounting bracket.
- Using a large pair of channel locks or a C-clamp, press the caliper piston back into its bore. Be sure the piston is not cocked, and that it is pressed in straight.
- Install the brake pads onto the mounting bracket.
When installing the brake caliper, ensure that the rubber boots are fit securely in the grooves.
- Install the brake caliper over the brake rotor, pads and mounting bracket.
- Install and tighten the guide pins to 19-2 ft. lbs. (25-30 Nm) for Samurai models, to 16-23 ft. lbs. (22-32 Nm) for Sidekick, Tracker and X-90 models, or the upper mounting bolt to 36 ft. lbs. (50 Nm) and the lower bolt to 42 ft. lbs. (58 Nm) for Sidekick Sport models.
- If equipped, install the guide pin caps.
- On Samurai models, install the anti-rattle clip on the outboard side of the caliper.
- Install the front wheels.
- Lower the vehicle, and fully tighten the wheel lug nuts.
- Depress the brake pedal repeatedly until a firm pedal is obtained. Do not attempt to drive the vehicle unless a firm pedal is obtained.
- Check the fluid level in the master cylinder. Add fresh brake fluid, as necessary.
- Road test the vehicle.
See Figure 2
To inspect the brake pad lining, remove the brake caliper without disconnecting the flexible brake hose from it. Then, inspect the brake pad lining for damage, such as crumbling, missing chunks, uneven wear, etc. Also, measure the combined thickness of the pad lining and the pad backing. The minimum allowable brake pad lining thickness should be as follows:
If there are signs of damage, or if the lining and backing thickness is less than specified, replace the pads with new ones.