SAFARI BSVI SERVICE MANUAL

BRAKES (EPB) 22 C. FRONT BRAKE CALIPER PAD REPLACEMENT 1. Keep the gear shifter lever in neutral position. 2. Apply the parking brake. 3. Jack the vehicle and remove the front wheel. 4. Loosen and remove the bottom sliding pin bolt. NOTE Before removing the sliding pin bolt, ensure that the pedal is fully depressed i.e. caliper is fully returned at zero condition. 5. Swing the caliper up, hold with one hand and then remove the pads one after the other. NOTE Front Caliper is equipped with SS clip on shim on outboard pads. While removing pads from caliper ensure no damage of SS shim. INSPECTION Measure the pad lining thickness if it is found to be 1mm or less anywhere, it has to be replaced. The inboard pads of front brakes are provided with the wear indicator. FRONT BRAKE PAD INDICATOR 6. Push the piston back into the cylinder till bottom, by use of C clamp or any other appropriate tool. 7. Use the SS clip on shim on outboard pads only. FITMENT For fitment follow the reverse procedure of removal & tighten the pin bolts to torque of 6.5±0.3 Kgm for front caliper. CAUTION  The inboard pads are provide with wear indicator assembly. Since the inboard pad and shims are not inter-changeable.  Do not polish the pads with sand or emery paper as hard particles of sand or emery paper will deposit on pad and may damage disc.  Do not contaminate pad surface with oil or grease.  Always use genuine recommended pads for replacement.  Brake pads have to be replace in sets only. If brake pads on left side are replace then brake pads on right side should also be replaced.  Apply brake pedal couple of times with the engine started before taking the vehicle for a road test. Before applying an emergency brake, it is advisable to apply the brake gently several times at 50 Km (30 miles) per hour to allow the brake pads to align. Heavy braking or prolonged braking should be avoided in the initial 100-150 km.(60-90 miles ) of run until the new pads are bedded. NOTE  While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc.  Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and make sure that the pads are sitting square with the disc without any tilt.  Before inserting the pads ensure that caliper is returned fully to its position. (Push the piston inside if necessary.) While pushing the piston inside care should be taken to avoid the damage to the cylinder. Use suitable tool if required for pushing the piston inside.  While replacing pads with new sets, replace pad slippers provided with pad kit. Also ensure 3m tape pasted slippers should be fitted on lower (trailing) side of the caliper.