Rear Brake Pad Inspection and Replacement

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

- Avoid breathing dust particles.
- Never use an air hose or brush to clean brake assemblies. Use an appropriate vacuum cleaner.

Inspection (Except KQ Model)

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.

1. Remove the rear wheels.

1. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the brake pad backing plate.

   Brake pad thickness:
   | Standard: | 8.9−9.1 mm (0.350−0.358 in.)
   | Service limit: | 1.5 mm (0.06 in.)

1. If the brake pad thickness is less than the service limit, replace all the pads as a set.

Replacement (Except KQ Model)

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.

1. Remove the rear wheels.

1. Remove the brake hose mounting bolt (A).

1. Remove the flange bolts (B) while holding the pin (C) with a wrench being careful not to damage the pin boot, and remove the caliper (D). Check the hose and pin boots for damage and deterioration.

1. Remove the pads (A).

1. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.

1. Check the brake disc for damage cracks.

1. Clean and install the pad retainers.

1. Apply Molykote M77 grease to the back of pads (A), and to the other areas indicated by arrows. Wipe excess grease off the pads. Contaminated brake discs or pads reduce stopping ability. Keep grease off the brake discs and pads.

1. Install the brake pads correctly.
   If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

1. Push in the piston (A) so the caliper will fit over the pads. Make sure the piston boot is in position to prevent damaging it when installing the caliper.

1. Install the caliper. Install the flange bolts (B), and tighten it to the specified torque while holding the pin (C) with a wrench being careful not to damage the pin boot.

1. Install and tighten the brake hose mounting bolt (D).

1. Press the brake pedal several times to make sure the brakes work, then test-drive the vehicle.
   NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

1. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

1. Install the rear wheels.

Inspection (KQ Model)

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.

1. Remove the rear wheels.

1. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the brake pad backing plate.

   Brake pad thickness:
   | Standard: | 8.9−9.1 mm (0.350−0.358 in.)
   | Service limit: | 1.6 mm (0.06 in.)

1. If the brake pad thickness is less than the service limit, replace all the pads as a set.

Replacement (KQ Model)

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.

1. Remove the rear wheels.

1. Remove the flange bolts (A) while holding the pin (B) with a wrench being careful not to damage the pin boot, and remove the caliper (C). Check the hose and pin boots for damage and deterioration.

1. Remove the pad shim (A) and pads (B).

1. Remove the pad retainers (A).

1. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.

1. Check the brake disc for damage cracks.

1. Clean and install the pad retainers.

1. Apply Molykote M77 grease to both sides of the shim (A), the back of pads (B), and to the other areas indicated by the arrows. Wipe excess grease off the shim and pads. Contaminated brake discs or pads reduce stopping ability. Keep grease off the brake discs and pads.

1. Install the brake pads and pad shim correctly. Install the pad with the wear indicator (C) on the inside.
   If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.

1. Rotate the piston (A) clockwise into the cylinder, then align the cutout (B) in the piston with the tab (C) on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly.

1. Install the caliper. Install the flange bolts (D), and tighten it to the specified torque while holding the pin (E) with a wrench being careful not to damage the pin boot.

1. Press the brake pedal several times to make sure the brakes work, then test-drive the vehicle.
   NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

1. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

1. Install the rear wheels.