Rear Disc

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





REMOVAL



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



1. Remove piston boot retainer with a screwdriver.

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

CAUTION: Do not scratch or score cylinder wall.




2. Push out piston and piston boot with compressed air.
3. 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 cylinder. Never use mineral oil.

Piston

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign objects. Replace if any of the above conditions are observed.

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
Rubbing Surface
Check rotor for roughness, cracks or chips.

Runout
1. Secure rotor to wheel hub with 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




Minimum thickness: 14.0 mm (0.551 inch)
Thickness variation (At least 8 portions): 0.02 mm (0.0008 inch) Max.

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


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.
4. Secure piston boot with retainer.


INSTALLATION

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




1. Install caliper assembly.
Do not forget to install shims and washers.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air.