Front Brake Rotor Replacement (J55)

Special Tools CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit Equivalent regional tools: Special Tools

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

Brake Dust Warning Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle
3. Remove the front tire and wheel assembly. Tire and Wheel Removal and Installation

Front Brake Rotor Replacement (J55) — figure 1

4. Front Brake Hose Bracket Bolt (1) » Remove

Front Brake Rotor Replacement (J55) — figure 2

5. Front Brake Caliper Bolt (1) » Remove [2x]

Front Brake Rotor Replacement (J55) — figure 3

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

6. Remove the brake caliper and support with heavy mechanics wire. (1)

Front Brake Rotor Replacement (J55) — figure 4

7. Front Brake Rotor Bolt (1) » Remove
8. Front Brake Rotor (2) » Remove Installation Procedure

Note

Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminates should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

1. Using the CH-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.

2. Using the CH-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.

3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure there are no foreign particles or debris remaining.

4. Front Brake Rotor (2) » Install

Caution

Fastener Caution

5. Front Brake Rotor Bolt (1) » Install and tighten — Fastener Specifications

6. Front Brake Caliper (1) » Install

7. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 7.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 7.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 7.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 7.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

8. Front Brake Caliper Bolt (1) » Install and tighten [2x] — Fastener Specifications

9. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

10. Install the front tire and wheel assembly. Tire and Wheel Removal and Installation

11. Remove the support and lower the vehicle.

12. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

13. Burnish the brake pads and rotors. 13.1. Select a smooth road with little or no traffic. 13.2. Accelerate the vehicle to 48 km/h (30 mph).

Note

Use care to avoid overheating the brakes while performing this step. 13.3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 13.4. Repeat steps 13.2 and 13.3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.