Front

Front Brake Assembly Components:

CALIPER REMOVAL





1. Disconnect brake hose.
Remove the union bolt and 2 gaskets from the Caliper, then disconnect the brake hose from the Caliper. Use a container to catch the brake fluid as it drains out.
Torque: 30 Nm (310 kg.cm, 22 ft. lbs.)

NOTE: Install the flexible hose lock securely in the lock hole in the caliper.

2. Remove Caliper.
(a) Hold the sliding pin and loosen the 2 installation bolts.
Torque: 34 Nm (350 kg.cm, 25 ft. lbs.)
(b) Remove the 2 installation bolts.
(c) Remove the Caliper from the torque plate.
3. Remove these parts:
^ 2 anti-squeal springs.
^ 2 Brake Pads with anti-squeal shims.
^ 4 pad support plates.

CALIPER DISASSEMBLY

Removing Cylinder Boot Set Rings And Boots From The Caliper:

1. Remove cylinder boot set rings and boots.
Using a screwdriver, remove the cylinder boot set rings and cylinder boots from the cylinder.





2. Remove pistons.
(a) Place a piece of cloth or similar article between the piston and the Caliper.
(b) Use compressed air to remove the pistons from the cylinder.

DISASSEMBLY CAUTION: Do not place your fingers in front of the piston when using compressed air.





3. Remove piston seals.
Using a screwdriver, remove the piston seals from the cylinder.
4. Remove sliding pins and dust boots.
(a) Remove the 2 sliding pins from the torque plate.

CAUTION: Insert the sliding pin with sliding bushing into the bottom side.





(b) Using a screwdriver and hammer, tap out the 2 dust boots.

NOTE: Use a 21 mm socket and tap in 2 new dust boots into the torque plate.

CAUTION: Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.

CALIPER ASSEMBLY
Assembly is in the reverse order of disassembly.

CAUTION: Apply lithium soap base glycol grease to the parts indicated by the arrows in EXPLODED VIEW of system.

CALIPER INSTALLATION
^ Installation is in the reverse order of removal.
^ After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Service and Repair