Front, rear, and complete brake kits with Alcon calipers and pre-assembled Pro Systems rotor assemblies.
1. Kit identification
| Kit | Part number |
|---|---|
| Complete kit: front and rear | BRK.200574 |
| Front axle kit | BRK.200575 |
| Rear axle kit | BRK.200576 |
| Component | Front | Rear |
|---|---|---|
| Caliper | 6-piston Alcon | 4-piston Alcon |
| Rotor dimensions | 380 × 36 mm | 375 × 28 mm |
| Left rotor part number | ROR.910417 | ROR.910443 |
| Right rotor part number | ROR.910418 | ROR.910444 |
| Rotor hat | HAT.101449 | HAT.101571, with parking-brake drum |
| Caliper bracket | BRT.101451 | BRT.101452 |
| Caliper mounting stud | STT.100120 | |
| Stud nut / washer | PSYMS7 / PSYWS7 | |
| Banjo kit | BRN.101381 short banjo, for use with OEM brake lines |
|
| Pad thickness | 18 mm | 20 mm |
Confirm the supplied kit matches the vehicle and the axle being serviced. Left and right refer to the vehicle's sides when seated facing forward. Wheel fitment and clearance must be confirmed separately before installation.
2. Preparation
- Check the kit contents: left and right calipers, left and right rotor assemblies, axle-specific brackets, mounting studs, nuts and washers, pads, and banjo hardware with sealing washers.
- Have suitable lifting equipment, axle stands, wheel chocks, torque wrenches, brake-line tools, a drain pan, and bleeding equipment available.
- Use fresh brake fluid meeting the vehicle's requirements. Keep fluid and grease off pads and rotor friction surfaces.
- Protect painted surfaces from brake fluid. Clean spills immediately using a method suitable for the affected finish.
- Inspect OEM flexible brake hoses. Do not reuse a damaged, cracked, leaking, or otherwise unserviceable hose.
3. Torque reference
| Fastener | Torque |
|---|---|
| Bracket Nut | 30 lbf-ft. |
| Brake hose banjo bolts | 156 in-lbs |
| Pad retaining bolts, where fitted | 18 lbf-ft / 25 N·m |
| Bleed screws | 12.5 lbf-ft / 17 N·m |
Do not over-tighten. Use the vehicle's factory service specification for bracket-to-knuckle fasteners and wheel fasteners. The caliper mounting-nut torque above is not a stud installation torque. Follow any hardware-specific instructions supplied with the kit.
4. Installation
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Secure and raise the vehicle
Park on a level surface and chock the wheels remaining on the ground. Raise the vehicle at the approved lifting points and support it securely on axle stands. Remove the wheels for the axle being serviced.
Never work beneath a vehicle supported only by a floor jack. When servicing the rear brakes, release the parking brake using the factory procedure after the vehicle is secured.
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Remove the original caliper and rotor
Disconnect the OEM brake hose at the caliper and contain the escaping fluid. Protect the open hose connection from contamination and do not allow the reservoir to run dry. Remove the original caliper and rotor using the factory service procedure. Never let a caliper hang from its brake hose.
For the rear axle, follow the factory procedure for releasing the rotor from the parking-brake shoes. Do not force the rotor off against engaged shoes.
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Check the dust / heat shield
Trial-fit the new components and inspect the shield for interference. Some trimming of the dust / heat shield may be necessary to clear the larger rotor and caliper. Trim only the areas needed, remove sharp edges and debris, and check clearance again. Protect the surrounding hoses, wiring, and parking-brake components during trimming.
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Prepare the hub and install the bracket
Clean the hub mounting face thoroughly. Remove rust, debris, and burrs that could prevent the rotor hat from seating flat. Inspect the hub and bearing; correct any damage or excessive play before proceeding.
Install the correct front or rear caliper bracket with the appropriate mounting hardware. Confirm its orientation and seating against the knuckle. Tighten bracket-to-knuckle fasteners to the applicable factory service specification. Install supplied mounting studs according to the kit's hardware instructions if they are not already installed.
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Install the correct rotor assembly
Match each assembly to the left or right rotor part number in the identification table. Seat the pre-assembled rotor squarely against the hub and secure it temporarily with suitable wheel-fastener hardware. Do not identify rotor direction by the appearance of the slots alone.
Rotate the assembly by hand and check shield and bracket clearance. On the rear axle, verify the parking-brake shoes fit correctly inside the new hat's drum. Inspect and adjust the parking brake according to factory service information.
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Install the caliper and pads
Confirm the caliper is correct for the side and mounting position. The bleed screws must be at the top when installed. Follow any caliper direction markings; do not exchange left and right calipers to make the hose connection fit.
Fit the caliper over the rotor. Install the hardware, then torque to spec. Check that the rotor is correctly positioned within the caliper and rotates without mechanical interference.
If pads are not already installed, fit the correct axle-specific pads and secure them with the supplied retaining hardware in its intended arrangement. Do not split the caliper body. Verify that the pads are fully seated, correctly retained, and do not overhang the rotor's outside diameter.
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Connect the OEM brake hose
Retain the OEM brake hose and connect it to the new caliper using the supplied BRN.101381 short banjo hardware. Use new sealing washers, with one on each side of the hose's banjo fitting. Start the bolt by hand and orient the hose before final tightening.
Confirm the hose is not twisted, kinked, stretched, or touching the rotor, wheel, or other moving components. On the front axle, check routing from full left to full right steering lock. Check hose clearance through the relevant suspension movement on both axles.
Torque the banjo bolt to 156 in-lbs. Recheck hose routing after tightening.
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Complete the opposite side
Repeat the installation on the other side of the axle. For a complete kit, complete both axles before bleeding. Recheck every mounting fastener, pad retainer, hose connection, and component clearance.
5. Bleeding and hydraulic checks
Bleed the system using the vehicle's factory bleeding sequence and any required ABS service procedure. Where a caliper has separate outboard and inboard bleed screws, bleed the outboard screw first, then the inboard screw, unless the vehicle or caliper instructions specify otherwise. Bleed every applicable screw.
- Monitor the reservoir throughout the procedure and keep it above the minimum level.
- Continue until air is removed and the pedal is firm. Tighten bleed screws to 11-12.5 lbf-ft / 17 N·m.
- Clean residual fluid from the bleed screws and hose connections so fresh leaks can be identified.
- With the vehicle stationary, apply and hold firm pedal pressure while checking all hydraulic connections for leaks.
- A spongy pedal requires further diagnosis and bleeding. A pedal that sinks under sustained pressure requires diagnosis before the vehicle is driven.
6. Final inspection and first use
- Verify all pads and retaining hardware are secure, and all installation fasteners have been tightened correctly.
- Install the wheels, confirm clearance, and tighten wheel fasteners to the factory specification. Lower the vehicle safely.
- Apply the brake pedal to seat the pads before moving the vehicle. Confirm a firm pedal with adequate travel remaining.
- Check fluid level and the rear parking-brake operation, where applicable.
- Test braking initially at walking speed in a safe, controlled area. Confirm consistent braking and check for abnormal noise, pulling, or rubbing.
- After the initial check, inspect again for fluid leaks and evidence of component contact. Stop and investigate any abnormal condition before normal use.
No additional bedding procedure is required for the supplied pre-bedded pads and rotors. The initial low-speed check verifies installation and brake operation. When replacement pads or rotors are installed later, follow the bedding instructions for those replacement components.