Refit

3. Remove 2 bolts, front brake caliper to suspension hub.

4. Move caliper aside and tie clear of brake disc.
5. Remove 2 screws securing brake disc to drive flange.
6. Remove brake disc from drive flange, using jacking screws if necessary.

Refit

CAUTION: Excessive disc run – out can exist after fitting a new disc, with no immediate symptoms being evident during driving. The most likely cause of run – out is the presence of contaminants (e.g. rust or paint) or damage on mating faces of flange and disc, and disc and wheel. Excessive run – out will cause progressive uneven wear of the disc, leading to disc thickness variation, which is the cause of judder. Always ensure that the disc run – out checks given here are strictly adhered to.

1. Inspect mating surfaces of new disc and drive flange and clean thoroughly using wire brush.

Note: There is no need to remove the silver protective coating from the friction surface of a new disc.

2. Fit brake disc to drive flange and secure using 4 x M12 nuts (not the wheel nuts). Tighten nuts to 70 Nm.

3. Mount a dial test indicator to caliper lower mounting hole using tool 18G 191-9.
4. Position dial test indicator probe 6 mm from disc outer edge.
5. Rotate disc at least one complete turn and measure disc run – out.
   Front disc run – out limit with wheel off = 0.050 mm.

Run – out exceeds limit

6. Mark disc to drive flange relationship, remove 4 x M12 nuts retaining disc and remove disc from drive flange. Check mating surfaces again for contaminants then refit disc 180° from previous position and secure with nuts. Recheck run – out.
7. If run – out is still excessive, skim brake discs using an on car disc lathe.
8. If a lathe is not available, fit new drive flange and/or bearings and recheck run – out.

Run – out within limit

9. Remove dial test indicator and tool 18G 191-9. Remove 4 x M12 nuts and secure disc with the new screws tightened to 6 Nm.
10. Wipe pads and shims clean.
11. Fit shims to pads.
12. Position brake pads and locate caliper assembly to disc.
13. Secure caliper using top mounting bolt only.
14. Inspect wheel and disc mating surfaces and remove any contaminants.
15. Fit road wheel and tighten nuts to 100 Nm.