Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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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 OSHA-approved vacuum cleaner. Inspection 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the rear wheels. 3. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. 4. If any of the brake pad thickness is less than the service limit, replace the rear brake pads as a set. 5. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear wheels. Replacement 1. Remove some brake fluid from the master cylinder. 2. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 3. Remove the rear wheels. 4. Remove the brake hose mounting bolt (A). 5. Remove the flange bolts (B) while holding respective caliper pin (C) with a wrench. Be careful not to damage the pin boot, and remove the caliper (D). Check the hose, the pin boots, and the parking brake cable boots for damage and deterioration. NOTE: Do not twist the brake hose and the parking brake cable to prevent damage. 6. Remove the pad shim (A) and the brake pads (B). 7. Remove the pad retainers (A). 8. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 9. Inspect the brake disc, and check for damage and cracks. 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows and shaded area). 11. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off the brake disc and the brake pads.

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Step 1: Lift the car using a lift or jack stands and remove all of the following: – - – Wheels Front Undertray – Use Phillips Head Screw Driver Front Bumper If You Find It Easier To Do So Now, Otherwise, It Can Be Removed Later – Use 10mm Socket and Flat Head Screw Driver Step 2: Remove the two 19mm caliper bolts and washers from the back side of each front caliper. – Use 19mm Socket * Note: The caliper should not move from it’s resting position too much once the bolts are removed, but please be cautious and wary that the caliper may shift slightly due to it’s weight as the bolts are removed. It is also EXTREMELY IMPORTANT to be sure to save the four washers removed in this step. They are a required component used later on during installation. Step 3: Use the supplied 10mm Allen Head bolts, Stainless Steel spacers, the Caliper Ducts, and the washers removed in Step 2 and attach the caliper ducts to the spindle. It is important to assemble these parts in the proper order outlined below: – OEM Washer – Caliper Duct Mounting Hole – Stainless Steel Spacer – 10mm Allen Head Bolt – Use a 10mm Allen wrench to hand-tighten this bolt to the spindle and caliper. Note: Please ensure that the OEM washer is re-used and that it contacts the spindle before the caliper duct. Also, ensure that the caliper duct is positioned so that the Forge logo is facing the front of the vehicle. The caliper ducts ARE NOT side-specific, so either duct can be used on either side of the car. Step 3 cont.: Here is a picture showing the 10mm Allen wrench tightening down the 10mm Allen bolt. Once installed, this is how the caliper duct should look:

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CAUTION: Use only DOT 3 brake fluid from a sealed container. NOTE: ABS bleeding requires conventional bleeding methods (manual or pressure) plus ABS bleeding method (using scan tool). See MANUAL BLEEDING or PRESSURE BLEEDING plus ABS BLEEDING . Bleed system using either conventional bleeding method, then using ABS bleeding method. Repeat conventional bleeding method. Observe following precautions during brake bleeding procedure. DO NOT allow master cylinder to run out of fluid when bleeding brakes. Check fluid level frequently and add fluid as necessary. DO NOT pump brake pedal during bleeding procedure unless directed to do so. Bleed only one brake system component at a time. Use a bleed hose on each wheel cylinder and caliper bleed screw. Be sure to tighten each bleed screw when bleeding is complete. If master cylinder has been overhauled or a new cylinder is to be installed, bench bleed master cylinder before installation. MANUAL BLEEDING 1. Fill master cylinder. Install clear vinyl bleed hose onto left rear bleed screw. Place other end of hose in clean transparent container. 2. Partially fill a container with clean brake fluid. Submerge end of hose in fluid. Pump pedal 3-4 times and hold. Open bleed screw at least one turn. 3. Close bleed screw. Release pedal. Repeat procedure until flow of brake fluid is clear and free of bubbles. Proceed to next bleed screw of brake bleeding sequence. See BLEEDING SEQUENCE table.

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REMOVAL 1. Lift up the vehicle and remove the wheel and tire. Disconnect the wheel speed sensor from the knuckle. 3. Disconnect the brake hose from the knuckle. 4. Remove the caliper assembly and suspend it with wire. 5. Remove the split pin and drive shaft nut from the front hub. 6. Remove the 2 bolts and disconnect the ball joint from the knuckle. 7. Using a plastic hammer, disconnect the drive shaft from the axle hub. 8. Using the special tool, disconnect the tie rod end from the knuckle. NOTE: 1) Be sure to tie a cord to the special tool and to a nearby part. 2) Loosen the nut but do not remove it. 9. 10. 11. 12. Loosen the upper arm mounting nut but do not remove it. Using the special tool, disconnect the upper arm from the knuckle. Remove the front axle and knuckle together. Installation is reverse of removal. DISASSEMBLY 1. Remove the brake disc from the hub. 2. Remove the snap ring. 3. Using the special tool, disconnect the hub from the knuckle. 5. Using the special tool, remove the wheel bearing outer race from the knuckle. INSPECTION 1. Check the hub for cracks and splines for wear. 2. Check the snap ring for crack or damage. 3. Check the knuckle inner surface for scoring and cracks. REASSEMBLY

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CAUTION: 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 OSHA-approved vacuum cleaner. 1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake hose mounting bolt (A) from the knuckle. 3. Hold the caliper pin with a wrench, being careful not to damage the pin boot. Remove the caliper bolt (B) with another wrench. 4. Pivot the caliper (C) up out of the way. Check the hoses and pin boots for damage and deterioration. 5. Remove the pad shims (A), pad retainers (B), and pads (C). The ‘99-01 models have two pairs of pad shims. The ‘02 model has one pair of the pad shims. 6. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate (A) thickness. 7. If the brake pad thickness is less than the service limit, replace the front pads as a set. 8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 9. Check the brake disc for damage and cracks. Install the pad retainers (A). Apply Molykote M77 grease or Daikalub 528D grease to both sides of the pad shims (A) and the back of the pads (B). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. 12. Install the brake pads and pad shims correctly. The ‘99-01 models have two pairs of the pad shims. The ‘02 model has one pair of the pad shims. Install the pad with the wear indicator (C) on the inside. NOTE: Check the brake fluid level, the brake fluid may overflow the reservoir if too full.