Installation and removal of the parts of the braking system involves first lifting and supporting the car in a safe position, then take off the wheel and tyre system. Then pull off the caliper and use mechanic wire to tie up the caliper but do not leave it hanging along the
Brake Hose. Most of the models, with exception of Navajo, remove the disc brake pads and mounting support. In 2WD Pickups and Navajo, first take off the dust cap, cotter pin, nut, washer and outer bearing before removing the brake disc off the spindle. In the case of a 4WD Pickup, loosen the locking hub or drive flange, snapring, spacer, set bolts, and bearing set plate and with an appropriate puller, loosen the bearing locknut and then loosen the hub and brake disc assembly without dropping the washer and bearing. In 4WD Navajo, all you need to do is to take off the locking hub and brake disc. In case of MPV models, loosen the screw to which it is attached and take out the brake disc. Check the brake disc for scoring, wear and runout and machine or replace when necessary. In cases where there is need to change the brake disc in pickup models, remove the attaching bolts to remove the brake disc and the hub. Installation Planning When fitting the brake disc, a brake disc-to-hub bolt on B Series pickups is tightened and brake disc wheel bearings must be changed. The shudder, vibration or the pulsation of the pedal during braking, which is referred to as brake roughness, can be caused by the accumulation of foreign material on the surfaces of the brake disc or over-brake disc variation. In case of contamination, hand sand the linings, and the brake disc surfaces. Squeal or squeak in brakes could be caused by the same problem and hard sanding could be used to overcome this problem. Never use unduly abused linings and ensure that the caliper piston is free of roll back release since a sticking piston may cause rapid lining wear and may cause brake disc damage. Make sure the caliper glides on top of the mounting pinrails; it is recommended to keep it lubricated. Brake discs are to be replaced in case of structural damage or excessive wear, which reduces to the minimum thickness or heavy scoring. Lathe turning can be used to solve minor brake disc scoring, whereas deep scoring normally occurs when the linings have been worn away to the rivets or the metal backings. To test brake disc runout, get rid of the end play in wheel bearings by adjusting the wheel bearing and clamp dial indicator to the steering knuckle assembly to test the runout of the brake disc in the lateral direction. When the reading of the total lateral runout is excessive, then ponder to change or resurface the brake disc.