Page 337 of 2490
9
. Remove brake discs. Refer to procedure 70.10.13.
1
0. Measure hub face run-out.
Position the gauge so that the pointer contacts the hub face.
Slowly rotate the hub one revolution, the hub run-out must not exceed the specification. Refer to
Specification Section <<204-02>>.
If the hub exceeds the maximum run-out specification replace the hub. Refer to operation
<<64.15.14>> .
11. If the hub run-out is within specification replace brake discs. Refer to procedure 70.10.13.
1
2. Install caliper to hub carrier.
Install and tighten bolts to 60 Nm.
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 339 of 2490

Front Disc Brake -
Lubri
cants, Fluids, Sealants and Adhesives
Torques - Brembo Brakes
Torques
Brake Tube, Hoses and Bracket Torques
CAUTI
ON: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
UnitS
pecification
Brake flu
id
ITT Supe
r Dot 4
Com
ponent
Nm
B
olt - anchor bracket to vertical link
18
0
Bo
lt - caliper to anchor bracket
DO
NOT REMOVE
Bleed n
ipple
12
-16
Hose u
nion to caliper
22
-26
Com
ponent
Nm
Bol
t - caliper carrier to vertical link
14
0
Guide
Pin - caliper housing to caliper carrier
25
-30
Com
ponent
Nm
Bleed n
ipple - front
4-
6
Bleed n
ipple - rear
8-1
1
Hose to fr
ont caliper
10
-14
Hose union to rear cal
iper - union bolt
30
-40
M1
0 hose locknut
15
-20
M10
brake tube female-nut
13
-17
M10
brake tube male-nut
13
-17
M12
brake tube male-nut
15
-20
M18
brake tube male-nut
22
-28
Brake tube clip retention
-bracket to body
4-
6
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 341 of 2490

• C
AUTIONS:
The Brembo caliper is aligned to the brak e disc when it is first installed to the vehicle, therefore, care must be taken
not to disturb this alignment. When removi ng the caliper; remove the bolts that secure the anchor bracket to the vertical
link only. DO NOT loosen any other caliper bolts.
Do not loosen bolts securing brake disc to disc mounting.
Brembo calipers and discs provide higher -performance braking using the existing hydraulic braking system. The brakes are
installed to the vehicle using unique vertical links, hubs, hydraulic hoses and disc shields.
The front brake disc consists of a ventilated, cross-drilled disc, bolted to a disc carrier. The disc assemb ly is mounted on the
wheel studs and clamped be tween the wheel and hub.
A unique feature of the front disc is th e slanted (non radial) ventilation webs which lean the opposite-way to the disc's
direction of rotation. This design enables he at generated by the disc to be dispersed by air entering at the disc's center and
being forced outwards through the cooling ducts.
Due to the use of fixed calipers in place of the standard floating caliper, certain lateral dimensions on the vertical link and
It
em
Par
t Number
De
scription
1—B
rake Disc
2—Caliper
3—Anch
or Bracket
4—Anchor Pl
ate to Vertical Link - Bolts
5—Brake Pad
s
6—Guide P
ins
7—Anti-r
attle Spring
8—Di
sc Shield
9—Brake Hos
e
10—Bleed Nipp
les
Front Disc Brake—
Brembo
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.
Page 343 of 2490

Front Disc Brake - Brake CaliperVehicles
With: Standard Brakes
Re
moval and Installation
Remov
al
W
ARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR
HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM
BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.
• CAUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
A new brake hose must be installe d when replacing a brake caliper.
The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the
condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
S
pecial Tool(s)
Brake Pedal
Hold Tool
JDS 9013
1. O
pen engine compartment and fit
paint work protection covers
to fenders.
2. Raise vehicle on a four-post lift.
3. Raise front of vehicle and support on stands. Refer to Section
100-02.
4. Remove front wheels. See Section 204-04.
5. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake hose.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect
a bleed tube and co
ntainer to the calipers.
O
pen bleed nipples.
6. Depress and hold down brak e pedal at the specified
measurement using special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
Page 344 of 2490
60
mm down from its released position.
7. Close bleed nipples on both calipers.
Remove bleed tub e
s and containers.
Tigh
ten front bleed nipple
to 4-6 Nm.
Tigh
ten rear bleed n
ipple to 8-11 Nm.
8. CAUTIO
N: A new brake hose
must be installed when
replacing a brake caliper.
Disconnect brake hose from brake tube.
1. Unscrew brake tube union nut.
2. Remove nut from hose.
3. Remove hose from bracket.
Fit plug to brake tube.
9.
Re
move brake hose from caliper.
Remove an
d discard brake h
ose.
Fit plugs
to caliper por
t.
10. Remove caliper housing from caliper carrier.
1. Remove anti-rattle spring.
2. Remove dust covers.
3. Remove guide pins.