Lancia Front Disc and Pad Replacement

⚠️ Safety: Brakes are critical. Use jack stands, never rely solely on a jack, and always verify model-specific torque settings.

• Jack and 2 jack stands
• Lug wrench and sockets
• Torque wrench
• Brake caliper piston tool
• Wire brush
• Brake cleaner
• New front discs and pads

1. Park on a flat surface, engage the gear/Park, and loosen the lug nuts.
2. Lift the car at the manufacturer's designated points and rest it on jack stands.
3. Remove the front wheel.
4. Inspect the disc, pads, brake hose, and ABS sensor.
5. Remove any clips and disconnect the wear sensor.
6. Unscrew the caliper and never let it hang by the brake hose.
7. Remove the old pads.
8. Remove the caliper bracket, if necessary, to remove the disc.
9. Unscrew the disc retaining screw and remove the old disc.
10. Thoroughly clean rust and dirt from the hub.
11. Compare the new disc with the old one to verify compatibility and dimensions.
12. Clean the new disc with brake cleaner.
13. Install the disc onto the hub and tighten the screw to the specified torque.
14. Reinstall the caliper bracket and tighten the bolts to the specified torque.
15. Check the brake fluid level before retracting the piston.
16. Slowly retract the piston using the appropriate tool.
17. Install the new pads into their respective seats.
18. Reinstall the caliper and tighten its bolts to the specified torque.
19. Properly reconnect any wear sensor.
20. Check that the brake hose and cables are clear of the disc and moving parts.
21. Repeat the procedure on the other side: discs and pads must be replaced in pairs.
22. Reinstall the wheels and tighten the lug nuts with the torque wrench according to Lancia specifications.
23. Check the brake fluid level.
24. With the engine off, pump the pedal several times until it feels firm.
25. Visually check for any fluid leaks.
26. Perform an initial test at low speed in a safe area.
27. Check braking performance, noises, vibrations, and vehicle behavior.
28. Perform a break-in period, avoiding very heavy braking whenever possible during the first few kilometers.

• Do not use the jack as the sole support.
• Do not leave the caliper hanging by the hose.
• Do not contaminate discs and pads with oil or grease.
• Do not use generic torque settings.
• Do not drive if the pedal remains spongy or braking is abnormal.

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