Operation CHARM: Car repair manuals for everyone.

Front Disc

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.


in98q45xx_br-019b

REMOVAL

CAUTION: Suspend caliper assembly with wire so as not to stretch brake hose.




Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.





DISASSEMBLY

WARNING: Do not place your fingers in front of piston.

CAUTION: Do not scratch or score cylinder wall.

1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.

INSPECTION - CALIPER
Cylinder Body
- Check inside surface of cylinder for score, rust, wear, damage or presence of foreign objects. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

CAUTION: Use brake fluid to clean. Never use mineral oil.

Piston
Check piston for score, rust, wear, damage or presence of foreign objects. Replace if any of the above conditions are observed.

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface.

Main Pin, Pin Bolt And Pin Boot
Check for wear, cracks, rust or other damage. Replace if any of the above conditions are observed.

INSPECTION - ROTOR
Runout
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).





2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the specifications before measuring.

Maximum runout: 0.07 mm (0.0028 inch)

3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).


Rotor Thickness Inspection




Thickness variation (At least 8 positions): Maximum 0.01 mm (0.0004 inch)

If thickness variation exceeds the specification, turn rotor with on-car brake lathe.

Rotor repair limit: 26.0 mm (1.024 inch) Min.


ASSEMBLY



1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston.
3. Properly secure piston boot


INSTALLATION

CAUTION:
- Refill with new brake fluid "DOT 3".
- Never reuse drained brake fluid.




1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air.

BRAKE BURNISHING PROCEDURE
When experiencing soft brake pedal feel at very low mileage, or after replacing the rotor, burnish the brake pad contact surfaces according to the following procedures.

CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 10 times or more to complete the burnishing procedure.