B
BRAKES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
37
Repair and Service Manual
10002660
Fill the master cylinder with DOT 4 brake fluid and bleed
the brake system. (See BLEEDING AND FLUSHING on
page 38)
After bleeding the brake system, check for leaks along all
lines and at the master cylinder.
Brake Fluid
NOTICE: Hydraulic brake systems must be com-
pletely flushed if the fluid becomes contaminated.
To flush, bleed the entire system until all brake fluid
has been replaced with new DOT 4 standard auto-
motive brake fluid.
Keep the fluid in the master cylinder (1) at the correct fluid
level. The master cylinder is mounted to the frame behind
the driver side front wheel (Ref. Fig. 1). To prevent con-
tamination when checking fluid, clean the fill cap before
removing it. Check reservoir fluid level as indicated in the
Periodic Service Schedule (See PERIODIC SERVICE
SCHEDULE on page 133). When required, add clean
brake fluid to maintain fluid level 1/4” (6 mm) from top of
reservoir. Use new DOT 4 standard automotive brake
fluid.
Total brake fluid capacity for the complete hydraulic brake
system is 13 fl. oz.
REPLACEMENT OF WEAR ITEMS
Brake Pads Replacement
Tool List
Qty.
Allen Socket, 3/8” ........................................................ 1
Ratchet ....................................................................... 1
Channel Lock Pliers .................................................... 1
Torque Wrench, ft. lbs. ................................................ 1
Torque Wrench, in. lbs................................................. 1
Socket, 1/2” ................................................................. 1
Socket, 13mm ............................................................ 1
Wrench, 1/2”................................................................ 1
Wrench, 13mm ............................................................ 1
NOTICE: The front and rear brake pads must be
replaced as a full set.
Replace the brake pads as a full set on both wheels. To
remove the brake pads, lift and support the vehicle (See
LIFTING THE VEHICLE on page 8).
1.
Remove the wheel (See WHEEL AND TIRE SER-
2.
Remove the banjo bolts and crush washers securing
the brake lines to the caliper.
3.
Loosen the 2 socket head slider pins (15), but do not
remove them.
4.
Remove the two hex head screws (14) securing the
caliper (13) to the mounting bracket (18) (Ref. Fig.
3).
Fig. 3 Brake Caliper
5.
Swing the caliper (13) free from the rotor.
6.
Remove both anti-rattle springs (17).
7.
Use channel lock pliers to compress the side with the
O-ring.
8.
Remove the brake pads (16) one at a time.
9.
Compress the caliper piston. When the piston is
compressed, it will stay in position until the brake
pedal is pressed.
10. Compress the side with the O-ring and hold while
installing the new pads (16). When both pads are
installed, release pressure on the side with the O-
ring.
11. Separate the brake pads (16) and put the caliper (13)
over the rotor.
12. Install the two socket head slider pins (15) finger
tight.
13. Install the two hex head bolts (14) to attach the cali-
per (13) to the mounting bracket (18).
14. Reconnect the brake line using new crush washers.
15. Tighten all hardware to torque values specified
below.
16. Replace the wheel and tighten the lug nuts (See
Wheel Installation on page 128).
17. Bleed the brake system. (See BLEEDING AND
Item
Torque Specification
14
205 - 215 in. lbs. (23 - 25 Nm)
15
25 - 35 ft. lbs. (34 - 47 Nm)
Brake Line Banjo Bolt
17 - 20 ft. lbs (23 - 27 Nm)
14
15
13
16
17
13
18
Front of Vehicle
