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first push back the pads fully ! remove dust cover if there is one , remove clips from the pins that hold the pads in place then the pins and then remove the pads ! clean the area where the pads slide witha file gently ! see if pads fit freely then put a small amount of copperslip on the edges of the pads , fit pads , pins , clips and pump up the brakes ( first make sure the fluid is full then after you pump up , top up ) ! bed the pads in for a few miles using the brakes more than usual ! Bobs your aunty !
First, compress the calipers by using a large flat bladed screwdriver between the rotor and the piston side of the caliper. Next, remove the small rubber plug on the lower side of caliper and then remove the 5mm hex head screw. Once the screw has been removed the pads should fall out. Install new pads making sure the top end is securely in the slot at the top of the caliper. Then push the pads into the caliper and replace the screw that holds the bottom in.
Next, you might want to consider purchasing a repair manual if you are planning on performing your own maintenance. http://clymer.com/SearchResults.aspx?t=VT%201100&y=2002&mid=125&mn=Honda&
Their is a flat head screw on the callipar. Unscrew it first. Inside of the flathead screw is an allen wrench nut. Break the allen wrench nut loose. Now unscrew the two bolts that hold the calipar in place. Remove them completely. Slide the calipar off from the disc. Finishing unscrewing the allen head nut that we talked about earlier. Pull it all the way out. Remove the shoes unless they fall out.. Easy to take out.. Blow off the calipar. Replace the shoes. Now put that Allen head screw back in that holds the shoes in place. No need to tighten it yet. Just snug. Spread the shoes apart by using a screwdriver being careful not to damage the pads. Large screwdriver. Slide the calipars over the disc and now put some locktight onto those two mounting bolts for the calipars. Tighten to about 40 lbs. Now tighten the allen set screw that holds the shoes in place. Replace the flattip screw that covers the allen head. Use a impact driver to tighten by hitting it once. Pull on break handle about 4 times to set the shoes to the disc. Do this before you start your bike.. You have brakes.. It was easy.. Way to go!!!
I believe that the rear discs are warped or the tires are out of round when braking. More likely, the discs.
--- The following are the instructions for replacing the front and rear pads for the front/back rotors.
1999-01 Grand Cherokee Front
Drain 2?3 of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid. If equipped with anti-lock brakes, relieve the system pressure.
Raise and safely support the vehicle.
Remove the wheels.
Insert a small prybar through the caliper opening and pry the caliper (using the outboard brake pad) to bottom the pistons in the caliper bore.
NOTE: This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.
Pry the caliper support spring out of the caliper.
Remove both caliper slide pin bushing caps and slide pins.
Lift the caliper from the anchor.
Using a piece of mechanics wire, support the caliper so there is not tension on the brake hose.
Remove the brake pads from the caliper.
Fig. 2: Installing the inward brake pad on the front caliper pistons - 1999-01 Grand Cherokee
To install:
Position the brake pads onto the caliper.
Position the caliper into place on the anchor.
Coat the caliper slide pins with silicone grease and torque them to 21-30 ft. lbs. (29-41 Nm). Install the slide pin bushing caps.
Install the caliper support spring in the top of the caliper under the anchor; then, install the other end into the lower caliper hole.
NOTE: Hold the spring in the caliper hole with your thumb while prying the spring end out and under the anchor.
Fill the master cylinder with fluid and bleed the brake system.
Before driving the vehicle, pump the brakes several times to seat the pads.
Drain 2?3 of the brake fluid from the front reservoir. Use the bleeder screw at the front outlet port to drain the fluid. If equipped with anti-lock brakes, relieve the system pressure.
Raise and safely support the vehicle.
Remove the wheels.
Insert a small prybar through the caliper opening and pry the caliper (using the outboard brake pad) to bottom the piston in the caliper bore.
NOTE: This will back the brake pads off of the rotor surface to facilitate the removal and installation of the caliper assembly.
Pry the caliper support spring out of the caliper.
Remove both caliper slide pin bushing caps and slide pins.
Lift the caliper from the anchor.
Using a piece of mechanics wire, support the caliper so there is not tension on the brake hose.
Remove the brake pads from the caliper.
Fig. 3: Installing the inward brake pad on the rear caliper piston - 1999-01 Grand Cherokee
To install:
Position the brake pads onto the caliper.
Position the caliper into place on the anchor.
Coat the caliper slide pins with silicone grease and torque them to 21-30 ft. lbs. (29-41 Nm). Install the slide pin bushing caps.
Install the caliper support spring in the top of the caliper under the anchor; then, install the other end into the lower caliper hole.
NOTE: Hold the spring in the caliper hole with your thumb while prying the spring end out and under the anchor.
Fill the master cylinder with fluid and bleed the brake system.
Before driving the vehicle, pump the brakes several times to seat the pads.
Special tool is a 1" cube with tabs on each side that fits into indentations on the brake piston and can be purchased for $10-12 @ most discount parts stores. Use 3/8" ratchet with short extension and 'special tool to carefully turn piston onto internal hand brake screw. Take care to not tear dust boot. When piston is fully collapsed, make sure to align piston indentations perpendicular to brake pad as there are bumps on pad that fit into them. Also while screwing in piston either remove about 2/3 of brake fluid in master cylinder and refil afterwords or open the bleeder valve on brake piston assembly. Bleed if necessary.
For a wrench or for the acctual bolt size.
To remove front pads..you need 8mm allen socket to pull the caliper guide pins, then 17 or 18mm..To remove rear pads...you need 13mm socket for lock bolt on guide pins and 15mm open end wrench (thin section to hold guide pin while you remove lock bolts..I ground down a spare wrench). You DO NOT have to remove rear carriers to change rotors..just remove lock screw and angle rotor out. The B5 Passats don't have the electronic parking brake so you don't need VAG Com to change pads. Installation tips: Clean and regrease the guide pins with "synthetic caliper grease" Rear lock bolts come with preapplied thread locker and "are not to be reused"..I just wire brush the threads and use some Loctite Blue on em. I smear just a little antisieze on the inside bore of the rotors and on the lock screw threads to prevent corrosion and make next rotor change ez. Torques: Front caliper guide pins:18 ft lb Front carrier bolts: 89 ft lb Rear guide pin lock bolts:26 ft lb Wheel lugs: 89 ft lb
remove phillips scew and the door handle. remove padded arm rest on the door by lifting it up, and remove 2 screws. You can use a panel tool to remove the plastic toggle like pins holding the panel border in. Be as gentle as possible they may break due to becoming brittle.
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