Spark

Front Disc Brake Pads Replacement

Warning: Refer to Brake Dust Warning in the Preface section.

1. Inspect the fluid level in the master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluids needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .




Caution: Support the brake calliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the calliper in this manner will cause the flexible brake hose to bear the weight of the calliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

6. Remove the brake calliper lower guide pin bolt (1).



7. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire, or equivalent.
8. Remove the inboard brake pad (1) from the calliper mounting bracket (3).

Note the location of the brake pad audible wear sensor.

9. Remove the outboard brake pad (2) from the calliper mounting bracket (3).



10. Remove the brake pad retainers (1) from the calliper bracket (2).
11. Inspect the disc brake mounting and hardware. Refer to Front Disc Brake Mounting and Hardware Inspection .

1. Install a large C-clamp (1) over the body of the brake calliper (3), with the C-clamp ends against the rear of the calliper body and against an old inboard brake pad (2) or a wood block installed against the calliper pistons.
2. Tighten the C-clamp evenly until the calliper piston is compressed completely into the calliper bore.
3. Remove the C-clamp and the old brake pad or wood block from the calliper.



4. Install the brake pad retainers (1) to the calliper bracket (2).




Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position.

5. Install the brake pads (1, 2) to the calliper bracket (3).
6. Remove the support, and rotate the brake calliper into position over the disc brake pads and to the calliper mounting bracket.

Caution: Refer to Fastener Caution in the Preface section.




7. Install the lower brake calliper guide pin bolt (1) and tighten to 28 N·m (21 lb ft).
8. Install the tyre and wheel assembly. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle.
10. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake calliper pistons and brake pads.
13. Fill the master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling .
14. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .