Disc brake pads — replacement
Warning: Disc brake pads must be replaced on both front or both rear wheels at the same time — never replace the pads on only one wheel. Also, the dust created by the brake system is harmful to your health. Never blow it out with compressed air and don’t inhale any of it. An approved filtering mask should be worn when working on the brakes. Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use brake system cleaner only!
Note: This procedure applies to the front and rear brake pads.
Warning: Brake fluid will damage paint. If any fluid is spilled, wash it off immediately with plenty of clean, cold water.
1. Remove the cap from the brake fluid reservoir. Remove about two-thirds of the fluid from the reservoir, then reinstall the cap.
2. Loosen the front or rear wheel lug nuts, raise the front or rear of the vehicle and support it securely on jack stands. Block the wheels at the opposite end. Remove the wheels. Work on one brake assembly at a time, using the assembled brake for reference if necessary.
3. Inspect the brake disc carefully as out- lined in Section Brake disc — inspection, removal and installation. If machining is necessary, follow the information in that section to remove the disc.
4. Place a catch pan below the work area and clean the caliper, caliper bracket and surrounding area that you’ll be working on (see illustration).
4.4 Before disassembling the brake, wash it thoroughly with brake cleaner and allow it to dry
All models except 2500/3500 models with RPO J95/J96
5. Follow the accompanying photo sequence for the actual pad replacement procedure (see illustrations). Be sure to stay in order and read the caption under each illustration.
4.5a To make room for the new pads, use a C-clamp to depress the piston (s) into the caliper before removing the caliper and pads do this a little at a time, keeping an eye on the fluid level in the master cylinder to make sure it doesn’t overflow.
4.5b Front caliper mounting details
1 Caliper mounting bolts
2 Brake hose inlet fitting (banjo) bolt
3 Caliper mounting bracket bolts
4 Bleeder screw
4.5c If you’re replacing the front brake pads, remove the lower mounting bolt and pivot the caliper up, supporting it in this position with a piece of wire
4.5d If you’re replacing the rear pads, hold the caliper slide pin with an open-end wrench, loosen the lower mounting bolt with another wrench, then pivot the caliper up and support it with a piece of wire
4.5e Remove the inner brake pad
4.5f Remove the outer brake pad
4.5g Remove the upper and lower pad retainers and clean them. If they are cracked or distorted, replace them. Clean the bracket-to-pad retainer ma ting surface with a stiff wire brush, then wipe it clean with a rag. Apply a thin film of high- temperature brake grease to the mating to the back of the pads
4.5h Install the upper and lower pad retainers on the caliper mounting bracket
4.5i Lubricate the retaining clips only where the brake pad will touch the retaining clips
4.5j Install the inner brake pad …
4.5k … and the outer brake pad
4.51 Inspect the caliper upper mounting bolt /slide pin for scoring and corrosion, then lubricate it with high-temperature brake grease. If it was dry, remove the caliper mounting bracket, remove the upper mounting bolt/slide pin and lubricate it too
4.5m Before lowering the caliper over the pads, check the condition of the slide pin and the rubber boot, then lubricate the pin with high-temperature brake grease. Proceed to Step 18
2500/3500 models with RPO J95/J96
6. Using a C-clamp, depress the pistons into the caliper bores (see illustration 4.5a).
7. Remove the caliper mounting bracket bolts and detach the caliper and brake pads from the steering knuckle. Hang the caliper with a length of wire don’t let it hang by the brake hose.
8. Remove the outer brake pad.
9. Separate the mounting bracket from the caliper.
10. Remove the pad retainers from the bracket and install new ones.
11. Remove the inner brake pad from the caliper.
12. Remove the caliper guide pin seals and boots from the caliper and install new ones.
13. Remove the upper guide pin from the mounting bracket and install a new one.
14. Lubricate the guide pins of the caliper mounting bracket with high-temperature brake grease, then install the bracket to the caliper.
15. Install new pad retainers to the mounting bracket.
16. Install the new inner and outer pads.
17. Install the caliper/bracket/brake pad assembly over the disc and install the caliper mounting bracket bolts, tightening them to the torque listed in this Chapter’s Specifications.
All models
18. When reinstalling the caliper, be sure to tighten the mounting bolts to the torque listed in this Chapter’s Specifications. Tighten the wheel lug nuts to the torque listed in the Tune-up and routine maintenance Specifications.
19. After the job has been completed, slowly depress the brake pedal about two-thirds of its travel a few times until the pedal is firm. This will bring the pads into contact with the disc. Check the level of the brake fluid, adding some if necessary (see Tune-up and routine maintenance).
20. Break in the new pads by making a few low-speed stops. Allow time in between each stop for the discs to cool. Listen for any grinding noise or unusual mechanical noises that could indicate a problem with the brake system. After the test drive visually reinspect the brake system for leaks or any component not reinstalled properly.