Attention:
- Do not leave the caliper hanging on the brake hose, this will cause the hose to deform and brake fluid to leak. Tie the caliper with wire.
- If reinstallation of brake pads is planned, mark the pad installation locations and their orientation.
- If you plan to reinstall the brake pads, mark the locations of the adjusting shims.
- When replacing brake pads, the adjusting linings must be replaced at the same time.
1. Check the fluid level in the master cylinder reservoir.
2. If the brake fluid level is in the middle between the maximum and minimum level marks, then there is no need to remove the fluid from the reservoir before replacing the pads.
3. If the brake fluid level is above the middle, pump out the fluid to the middle between the marks.
4. Raise the vehicle and place safety stands under the frame.
5. Remove the front (or back) wheel.
6. To facilitate removal and correct subsequent installation of new pads, insert the brake caliper pistons into the caliper:
- place a large clamp on the caliper body and on the outer brake pad.
- slowly move the clamp jaws until the pistons are fully seated in the caliper.
- remove the clamp.
Series 1500
7. Loosen the brake caliper guide pin bolt.
Attention:
- When loosening and tightening the guide pin bolts, use only hand tools.
- When loosening and tightening the guide pin bolts, hold the guide pin with an open-end wrench. Do not allow the wrench to come into contact with the caliper.
8. Loosen the bolt (1) of the lower guide pin.
Front brake
Tightening torque 100 Nm.
Rear brake
Tightening torque 38 Nm.
Note: Apply locking adhesive to the bolt threads before installing.
9. Turn the brake caliper (2) upward until it stops in the bracket and tie the caliper with wire. There is no need to disconnect the brake hose.
10. Remove the brake pads (3).
11. Remove the brake shoe adjusting shims (4) from the support bracket (5). Do not reinstall the adjusting shims and guide pin bolts on the rear brakes.
12. Installation is carried out in reverse order.
Series 2500
7. Loosen the brake caliper guide pin bolts.
Front brake, example
Tightening torque 108 Nm.
8. Remove the brake caliper and tie the caliper to the frame with wire.
9. Remove the brake pads.
10. Remember the orientation of the brake pad wear sensor.
11. Remove and discard the adjusting shims. Do not reinstall the shims.
12. Installation in reverse order.
All models
13. After installation:
- a) Without starting the engine, slowly lower the brake pedal to approximately 2/3 of its full travel.
- b) Slowly release the brake pedal.
- c) Wait about 15 seconds and repeat steps (a) and (b) 7-8 times until you get a "hard" pedal and the brake pads are installed.
- d) Adjust the brake fluid level in the master cylinder reservoir.
- e) Latch the pads to the discs, see below.