Orlando

Front Brake Disc Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

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




1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
3. Install a C-clamp (1) over the body of the brake calliper, with the C-clamp ends against the rear of the calliper body and the outboard disc brake pad.
4. Tighten the C-clamp (1) until the calliper piston is compressed into the calliper bore enough to allow the calliper to slide past the brake rotor.
5. Remove the C-clamp (1).



6. Remove and DISCARD the brake calliper bracket bolts (1).




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.

Note: Do NOT disconnect the hydraulic brake flexible hose from the calliper.

7. Remove the brake calliper and the calliper mounting bracket as an assembly (1) 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.
8. Mark the position of the brake disc to the wheel studs.



9. Remove the brake rotor screw (2).
10. Remove the brake rotor (1) from the wheel hub.

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 CH-42450-A resurfacer , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange (1).
2. Using the CH-41013 resurfacer , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor (2).
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Install the brake rotor to the hub/axle flange. Use the mark made prior to removal to ensure proper orientation to the flange.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the brake rotor screw and tighten to 7 N·m (62 lb in).
6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Disc Assembled Lateral Runout Measurement .
7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Disc Assembled Lateral Runout Correction .
8. Remove the support, and install the brake calliper and the brake calliper bracket as an assembly to the steering knuckle.



9. Install NEW brake caliper bracket bolts (1) and tighten a first pass to 100 N·m (74 lb ft).

Warning: Refer to Torque-to-Yield Fastener Warning in the Preface section.

10. Tighten the NEW brake caliper bracket bolts a final pass to an additional 45 to 60 degrees, using the EN-45059 meter .
11. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
12. Lower the vehicle.