B
BRAKES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
87
Repair and Service Manual
634756
Rotor Replacement
The rotor (disc brake hub) is not designed to be trued
(“turned”).
If the rotor has deep grooves or gouges, it must be
replaced.
If the pad contact area has worn the rotor to 120" (3
mm) or less, the rotor must be replaced.
Swing the caliper and pads out of the way to gain access
to the rotor. See “Brake Pad Replacement” on page 86.
The disc hub (rotor) can be serviced in the same manner
as the hub on non-front disc brake equipped vehicles.
See FRONT SUSPENSION AND STEERING section for:
•
Hub Replacement
•
Wheel Bearing and Race Replacement
•
Wheel Bearing Packing
•
Wheel Bearing Adjustment
Spindle Replacement
See FRONT SUSPENSION AND STEERING section.
Actuator Linkage Bushings
Removing the front shield may improve accessibility to
brake components. (See BODY section).
Remove cotter pin and washer that secures the lower
actuator pivot to the acuator linkage. Discard cotter pin;
retain washer for reuse.
Install new nylon bushing, flange down, to the lower actu-
ator pivot.
Reconnect the actuator linkage using washer and a new
cotter pin.
Actuator Pivot Bushings
Removing the front shield may improve accessibility to
brake components. (See BODY section).
Both the upper and lower actuator pivots contain an ace-
tal flanged bushing at both ends of the actuator and are
unlikely to require replacement.
The upper actuator pivot also is fitted with a nylon bush-
ing between it and the brake cylinder clevis. To replace
any of these bushings, the actuator linkage must be
removed from the lower actuator pivot and the linkage
rod. See “Actuator Linkage Bushings” on page 87.
Remove the cotter pin and clevis pin securing the upper
actuator pivot and master cylinder clevis.
Remove lock nut and shoulder bolt to remove pivot com-
ponents.
Bushings may now be removed and replaced with new
ones. Be sure to replace the nylon bushing with the
flange facing upward.
Reassemble using new cotter pins.
Tighten lock nut to 5 - 10 ft. lbs (7 - 13 Nm) torque.
BLEEDING BRAKES
Tool List
Qty.
Hose ........................................................................A/R
Clean Container...........................................................1
Brake Fluid, DOT 3 ..................................................A/R
Wrench, 1/4" Box End..................................................1
General Information about Bleeding Brakes
The hydraulic brake system must be free of air to operate
properly. Air can enter the system when hydraulic parts
are disconnected for servicing or replacement, or when
the fluid level in the master cylinder reservoir is very low.
Air in the system will give the brake pedal a spongy feel-
ing upon application.
An assistant is required to perform this procedure.
Use a clean cloth to wipe off the master cylinder reservoir
and wheel cylinder bleeder valves (Ref. Fig. 35). Clean
each fitting before opening to prevent contaminating the
system.
Open the master cylinder reservoir and top off with stan-
dard automotive DOT 3 brake fluid.
Never reuse any excess fluid or return to origi-
nal container. Dispose of brake fluid properly.
Brake fluid should never be returned to the original con-
tainer and reused due to the possibility of contamination
by dirt, grease, moisture or used brake fluid. Contami-
nated fluid could cause failure of the braking system. Dis-
