Disc Installation Guide

1. Dismantle the wheel

Unscrew the nuts and mark on the rim and bolts to ensure they can be reinstalled in original positions

2. Check the wheel

Check the swelling, cracking, eccentric wear and aging of the tire etc. 

3. check the brake disc

Check the wear of disc surface and if the thickness is no less than the minimum thickness. If any, replace the disc immediately

4. compress the brake cylinder

Use a “C” type clamp to compress the brake cylinder and remove the bolts for installing caliper

5. remove the guide pin

Remove the guide pin of brake cylinder and check if it is worn and bent etc.

6. remove the caliper

Lift the caliper to remove it, and fix the caliper with metal hooks

7. remove friction linings for inspection

a. Remove friction linings from the mounting bracket of caliper or caliper assembly

b. Identify the inner pads and outer pads and mark the position of wear sensor

8. remove the bracket

Unscrew the mounting bolts of the bracket and remove the bracket

9. remove the brake disc

Remove the brake disc

10. clean the flange

Thoroughly clean the mounting flange surface of hub bearing and the internal surface of the mounting hole 

11. check the hub

First check if the hub bearing is loosening and then the sectional runout of flange plate is in compliance with the vehicle manufacturer’s specifications

12. clean the bracket

Thoroughly remove rusts and dirt from the mounting bracket of caliper and dirt from the guide pin hole

13. check the guide pin

Replace the dust cover, lubricate the guide pin and check if properly fit

14. install the guide plate (if any)

Remove the brake disc

15. clean the brake disc

Thoroughly clean the external and internal surfaces of the disc and apply an anti-rust coating for new disc

16. carry out rust protection for flange

Apply a thin layer of lubricant on the flange plate of bearing

17. install the brake disc

Install the disc onto the hub

18. install the bracket

Tighten the bolts with the torque specified by manufacturer

19. check the brake cylinder

Check if the caliper piston and dust seal are damaged or leaking. If necessary, repair or replace them

20. install brake pads

Install brake pads onto the guide plate of caliper fixing bracket and check if they are properly installed

21. install the caliper

Slide the caliper through brake pads to the fixing bracket

22. install the caliper
 

• Lubricate the guide pin hole with silicone grease
  
• Tighten the bolt of guide pin with the torque specified by vehicle manufacturer

23. check the brake system

Apply the brake pedal repeatedly before starting the vehicle until the brake pedal gets pressure

24. install the wheel

Install the wheel at the position marked previously. Tighten the bolts with the torque specified by manufacturer

25. FINISH THE INSTALLATION AND TEST THE VEHICLE