2. Inspect the thickness of the friction material on each pad. If at least one of them is at or below the specified minimum thickness, replace the entire set (four pads) in the following way.
Pic. 9.2. Removing the pad retaining pin
3. Press out the studs holding the pads by pressing on their inner ends using a punch.
Pic. 9.3. Properly positioned disc pad springs - indicated by arrows
4. Remove the springs (photo).
Photo 3.4 Removing the disc pad spring
5. Using a pair of pliers, pull out the outer shoe (photo).
Photo 3.5 Partially removed external disk pad.
6. Remove the inner block. If it is very tight, move the pad slightly to the side to press the caliper piston (photo).
Photo 3.6 Removing the inner disc pad.
7. To install new, thicker pads, you need to press the caliper piston completely into its cylinder using a flat metal rod, such as a tire lever. Pushing the piston will cause the fluid in the reservoir to rise, so anticipate this by pumping out some fluid using an old (pure) hydrometer or something similar.
8. Brush the cheeks of the caliper without inhaling the powder.
9. Insert the pads, making sure the pad side is against the disc. If you are installing disc pads made by the vehicle manufacturer, you may find that two out of four pads have white marks on their back plates. If this is the case, then the marked pads should be installed on the piston sides of the calipers. On new ATE brake units, a washer may be installed between the inner brake pad and the caliper piston. In this case, make sure that the washer is inserted with the inner pad (photo).
Photo 3.9 Internal disc pad and washer of ATE type brake assembly.
10. Correctly position the expansion springs (Pic. 9.3), and then insert the retaining pins (photo).
Photo 3.10A Insert the disc pad stud
Photo 3.10B Reassembled disc pads.
11. Repeat these steps on the opposite brake.
12. Install the wheels and lower the machine.
13. Press the brake pedal firmly several times until the pads are in the correct position in relation to the discs.
14. Add fluid to the reservoir to the required level.
15. New brake pads need to break in, so avoid hard braking if possible during the first 120 miles (200 km).
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