Page 316 of 2490

Road test the veh
icle and a
pply the brake pe dal lightly.
1
Do th
e brakes lockup?
Yes GO to H2
.
No
Vehicle is OK.
H2: INSPECT BRAKE PADS
Inspect brake pads for con
t
amination,
correct installation , damage and type.
1
Ar
e any concerns found?
Yes CHECK the front brake pads. For additi onal information, refer toSection 206
-03 Fr
ont Disc Brake
.
CHECK
the rear brake pads. For additi
onal information, refer toSection 206
-04
Rear Disc Brake
.
INST ALL new brake pads as ne ce
ssary. REPEAT
road test.
No GO to H3
.
H3: INSPECT BRAKE CALI
PERS
Inspect brake cali
pers for bindi
ng, leaking or sticking.
1
A
r
e any concerns found?
Yes CHECK the front brake calipers. For addi tional information, refer toSection 206
-03 Fr
ont Disc Brake
.
CHECK
the rear brake calipers. For addi
tional information, refer toSection 206
-04
Rear Disc Brake
.
IN ST
ALL the brake calipers correctly or INSTALL new
brake calipers as necessary. TEST the system for
normal operation. REPEAT road test if necessary.
No Vehicle is OK.
PI
NPOINT TEST I : BRAKES DRAG
TE
S
T
CONDITIONS
D E
TAILS/RESULTS/ACTIONS
I1
:
ROAD TEST VEHICLE
Ro
ad t
est the vehicle
and apply the brakes.
1
Are the brakes
functioning correctly?
Yes Vehicle is OK.
No GO to I2
.
I2
: CHECK CALIPERS
Check the fr
on
t caliper pistons for binding, leakin
g or sticking. For additional information, refer
toSection 206
-03 Fr
ont Disc Brake
. Check the rear cal
i
per pistons for
binding, leaking or sticking. For
additional information, refer toSection 206
-04
Rear Disc Brake
.
1
Do t
h
e disc brake caliper pistons
and pins bind, leak or stick?
Yes INSPECT the brake calipers and pa rking brake cables. INSTALL new co mponents as necessary. Road
test vehicle.
No GO to I3
.
I3
: CHECK BRAKE BOOSTER
Check the brake booster con
n
ecting rod alignment
and travel. For additional information, refer
toSection 206
-0 7
Power Brake Actuation
. 1
Is the co
nnecti
ng rod OK?
Yes Vehicle is OK.
No INSTALL a new brake booster. For addi tional information, refer toSection 206
-07
Power Brake
Actuation. TEST
the system for
normal operation.
PINPO
I
NT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
TE
S
T
CONDITIONS
D E
TAILS/RESULTS/ACTIONS
J
1
: TEST ON ROUGH ROAD
R
oad test the vehi
cle on rough road conditions.
1
Apply the brakes slowly. 2
Is th
e brake pedal ef
fort an
d brake pedal travel normal?
Page 319 of 2490

cap ven
t holes clogged or air in the hydraulic system.
Brake ped
al effort is excessive. This ma
y be caused by a bind or obstruction in the pedal/linkage, a faulty non return
valve, booster or insuffi cient booster vacuum.
R
ear brakes lock up during light pedal force. This may
be caused by damaged brake pads, an incorrectly adjusted
parking brake, a partially applied parking brake, a damaged ABS sensor or bearing failure.
Brake ped
al effort erratic. This condition could be caused by the brake booste
r or incorrectly installed brake pads.
Brake warning indicator i
s on. This may be caused
by low fluid level or float assembly damaged.
No
n Pressure Leaks
Any reduced fluid v
olume in the brake ma
ster cylinder reservoir condition may be caused by two types of none pressure
external leaks.
Type 1: An external leak may be occur at the master cylinder reservoir cap because of incorre ct positioning of gasket and
cap. Reposition cap and gasket.
Type 2: An external leak may occur at th e reservoir mounting seals. Repair such a leak by installing new seals and make
sure that the reservoir retainin g bolt is correctly installed.
Page 327 of 2490
3
. Remove brake pads from caliper.
1. Remove 'R' clips.
2. Withdraw pins from caliper.
3. Remove anti-rattle spring.
4. Remove brake pads.
4
.
C
AUTION:
Only remove the bolts securing the caliper anchor bracket to the vertical link. Refer to caution
above for more information.
C
AUTION:
Do not allow the caliper to hang on the hydraulic hose, as this will damage the hose.
Remove caliper from vertical link. Remove bolts.
Page 330 of 2490
14
.
CA
UTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid
spillage immediately from paint work, with clean water.
CA
UTION:
Note the condition of pins and 'R' clips and replace if necessary.
Install brake pads into caliper housing. Slowly retract caliper pistons.
1. Install pads.
2. Position anti-rattle spring.
3. Install pins.
4. Install 'R' clips.
15. Install wheels. Refer to operation <<74.20.05>>.
Page 335 of 2490
3
. Remove brake pads from caliper.
1. Withdraw pins from caliper.
2. Remove anti-rattle spring.
3. Remove brake pads.
4
.
C
AUTION:
Only remove the bolts securing the caliper anchor bracket to the hub carrier. Refer to caution
above for more information.
C
AUTION:
Do not allow the caliper to hang on the hydraulic hose, as this will damage the hose.
Remove caliper from hub carrier. Remove bolts.
Remove and tie caliper aside.
Page 338 of 2490
13
.
CA
UTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid
spillage immediately from paint work with clean water.
CA
UTION:
Note condition of pins and replace if necessary.
Install brake pads to caliper. Slowly retract caliper pistons.
1. Install pads.
2. Position anti-rattle spring.
3. Install pins - make sure pin collets are fully engaged into caliper.
14. Fit wheel. Refer to section <<204-04>>.
Page 340 of 2490

Front Disc Brake - Front Disc Brake
Description and Operation
The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through the
center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions.
The caliper carrier, which is se cured to the vertical link by two bolts, carries the single-pis ton caliper housing. The caliper
housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are applied the
caliper-housing piston pushes th e brake pad in front of it, towards the brake di sc. This movement forces the caliper housing
to move along the guide-pins, in the oppo site direction of the piston, to apply the second brake pad. The brake disc is
therefore gripped between the two pads. As brake pressure is increased the grip on the brake disc is increased to slow-down
the rotation of the road wheel.
The disc brakes requ ire no adjustment.
It
e
m
Par
t
Number
De
scr
iption
1—B
r
ake Disc
2—Caliper Housin
g
3—Caliper Carrier
4—Brake Pads
5—Guide P i
ns
6—Du
st
Covers
7—An
ti
-rattle Spring
8—Du
st
Shield
9—Brake Hos
e
10—Bleed Nipp
le
Page 342 of 2490

hub are critical to achieve correct clearan
ce and operation of
the brakes. Therefore special vertical links and hubs set within
a certain tolerance are inst alled with Brembo brakes.
The front discs are handed and must be fitt ed to the correct side of the vehicle. The left-hand disc can be identified by a
groove running around the circumference of the outer disc wall as shown in the illustration below.
Left hand disc - identification mark
Modified disc shields are installed to accommodate the larger diameter discs.
The four cylinder brake caliper is rigidly attached to the vert ical link via an anchor bracket. The caliper is a split assembly
with each side of the caliper, housing two pistons. The two-pairs of opposed pistons act direct ly on the brake pads mounted
one each side of the disc.
Stainless steel hydraulic hoses connect the calipers to the existi ng brake tubes. It is important that these hoses are aligned
correctly when installed to pr event them fouling on the steering and suspen sion components. Refer to operation 70.55.24
for information.
The Brembo disc brakes require no adjustment.