Rear Disc Brake Pads Replacement 1500 Series

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

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum-full point and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove 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.



6. Compress the brake caliper piston.

6.1.	Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.

6.2.	Slowly tighten the C-clamp until the piston is pushed completely into the caliper bore.

6.3.	Remove the C-clamp from the caliper.





Note: 

•	DO NOT use any air tools to remove the guide pin bolts. Use hand tools only.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brake are applied.

7. Using an open end wrench to hold the guide pin, loosen the guide pin bolt.

Caution: Support the brake caliper 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 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. Remove the guide pin bolt (1) from the brake caliper (2).
9. Rotate the brake caliper (2) upward until it stops on the caliper mounting bracket (5) and support the caliper with heavy mechanics wire or equivalent.

Note: 

•	If removing and installing the original brake pads and retaining springs, reference mark the position of the brake pads and retaining springs for proper installation.

•	DO NOT re-use the old brake pad retaining springs with new brake pads. Replace with NEW only.

10. Remove the brake pads (3) and retaining springs (4) from the mounting bracket (5).

1. Install the retaining springs (4) on the caliper mounting bracket (5).
2. Install the brake pads (3).

•	Install the new brake pads.

•	Install the original brake pads in their original position.

3. Remove the mechanics wire and rotate the brake caliper (2)  into position on the mounting bracket (5).
4. Install NEW caliper guide pin bolts.

Caution: Refer to Fastener Caution in the Preface section.





Note: 

•	DO NOT use any air tools to remove or tighten the guide pin bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the caliper guide pins in line with the caliper while removing or installing the caliper. DO NOT allow the wrench to come in contact with the brake caliper. Allowing the wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.

5. Use a open end wrench to hold the caliper guide pin while tightening the guide pin bolt to 38 N·m (28 lb ft).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
7. Lower the vehicle.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-9 until a firm pedal is obtained, to properly seat the brake caliper pistons and brake pads.
11. Fill the brake master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling.
12. Burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing.

Rear Disc Brake Pads Replacement 2500 Series

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

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove 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.
6. Compress the brake caliper pistons.

6.1.	Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad.

6.2.	Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.

6.3.	Remove the C-clamp from the caliper.

Caution: Support the brake caliper 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 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.




7. Remove the brake caliper guide pin bolts.
8. Remove the caliper from the caliper bracket and support with heavy mechanics wire or equivalent.



9. Remove the brake pads from the caliper bracket.

Note: Do not reuse the brake pad retaining springs.

10. Remove and discard the brake pad retaining springs.
11. Inspect the brake caliper. Refer to Brake Caliper Inspection.

1. Install NEW brake pad retaining springs to the caliper bracket.
2. Install the brake pads to the caliper bracket.



3. Install the caliper to the caliper bracket.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the brake caliper bolts and tighten to 108 N·m (80 lb ft).
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
6. Lower the vehicle.
7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
8. Slowly release the brake pedal.
9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained, to properly seat the brake caliper pistons and brake pads.
10. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.
11. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing.