5.30
Final Drive/Brake System
Phantom Lite Brake Pad Replacement
NOTE: Always replace both friction
pads at the same time.
Brake pads need to be replaced if the
th
ickness of the friction material is less
than 1/16" (.0625") / 1.5mm.
1. Clean the friction pad area and
master cylinder cover.
2. Remove the two caliper mounting
mou
nt bolts and slide the caliper
assembly off the disc.
3. Remove master cylinder cover.
4. Prior to removing old pads from
ca
liper, insert a large C-clamp placed on the head of
the banjo bolt and the backing plate, tighten C-clamp
carefully until piston is pushed back into the bore, do
not over tighten, Piston should move easily. If no C-
clamp is available insert a flat blade of large
screwdriver between pads and pry apart. This action
should press the caliper piston back into its bore, to
make room for the new pads. Monitor the master
cylinder during piston push back and remove any
excess fluid that is forced back into the reservoir to
prevent spillage.
5. Slide bracket tight to caliper and remove worn friction
p
ads and install the new pads making sure that the
friction material is facing inwards.
6. Insure slider bores are greased
well with silicone-
based grease.
7. Install bracket into slider bores.
8. Install new pads making sure that the friction material
is
facing inwards.
9. Reposition the caliper over the brake disc, insert and
to
rque mounting bolts to specification.
10. With the unit reassembled, actuate
the brake lever
lightly and slowly several times to seat the new pads
against the disc.
11. Check master cylinder reservoir for proper fluid level
an
d replace cover. Torque screws to specification.
12. Test brake system prior to returning vehicle to service.
Brake Caliper Mounting Fasteners:
20-22 ft-lbs (27-30Nm)
1/16(.0625" )/1.5mm
Brake Pad
Master Cylinder Reservoir Screws:
240-264 in-lbs (27-30Nm)
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