- loosen the rear wheel mounting bolts, then raise the rear of the vehicle and secure it on stands. Unscrew the mounting bolts and remove the wheel;
- remove the cap from the compensation tank with brake fluid;
- use a syringe to partially pump out the brake fluid from the reservoir;
- install the cap on the compensation tank with brake fluid;
Pic. 8.12. Parking brake cable attachment: 1 - a bolt of fastening of the bottom directing finger of a support; 2 - parking brake cable; 3 - lever
- Disconnect parking brake cable 2 from lever 3 (pic. 8.12);
- unscrew bolt 1 (see fig. 8.12) fixing the lower guide pin;
Pic. 8.13. LUCAS front brake caliper: 1 - cuff; 2 - piston; 3 - support; 4 - protective corrugated caps
- turn the caliper 3 on the upper guide pin (pic. 8.13) up;
- remove the brake pads from the caliper holder;
- clean dust and dirt from the caliper, and rust from the edge of the brake disc. If the pads are serviceable, clean them with a wire brush and rags. Clean the brake disc with HENKEL type solvent;
- check that there are no leaks of brake fluid from under piston 2;
- check the condition and proper fit of the cuff 1 and protective corrugated caps 4;
- check the brake disc for cracks, especially around the wheel bolt holes, as well as for wear or mechanical damage, and replace both discs if necessary;
- measure the thickness of the brake disc;
- make sure that the guide pins of the caliper slide freely;
- if necessary, replace defective parts;
Attention! Do not depress the brake pedal with the brake pads removed.
- press the piston into the caliper using the special tool DF 6.1 (you can press the piston into the caliper with a wooden rod or a hammer handle). At the same time, make sure that the piston is not warped and the surfaces of the piston and cuff are not damaged. When the piston is pushed in, the brake fluid is forced out of the brake cylinder into the compensation reservoir, so constantly monitor the fluid level in the reservoir, and if necessary pump out a small amount from the reservoir.
To install rear brake pads:
- install the brake pads in the rear brake caliper holder;
- lower the caliper down;
Attention! Lower the caliper carefully so as not to pinch the top guide pin.
- apply to bolt thread 1 (see fig. 8.12) fastening the guide pin with a locking compound that prevents its self-unscrewing, screw in the bolt and tighten it with a torque of 38 Nm;
- install the parking brake cable 2 and fasten it to the lever 3;
- replace the brake pads in the same way on the second rear wheel;
- check the brake fluid level in the reservoir, top up if necessary;
- start the engine and repeatedly, calmly and with increasing effort, press the brake pedal several times so that the brake pads are pressed against the brake disc.
Attention! After installing new brake pads, avoid sudden braking for the first 200 km of the vehicle.