Front

FRONT BRAKE
OVERHAUL

HINT: Overhaul the RH side using the same procedures as for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
a. Draw out fluid with syringe.

NOTICE: Wash brake fluid off immediately if it adheres to any painted surfaces.





3. REMOVE FRONT DISC BRAKE W/HOLE PIN
a. Remove the clip.
b. Remove the front disc brake anti-rattle Whole pin while pushing on the anti-rattle spring.
4. REMOVE FRONT DISC BRAKE ANTI-RATTLE SPRING

NOTICE: The anti-rattle spring and clip can be used again if they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

5. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 pads and the 2 anti-squeal shims from each pad.





b. Right wheel: Remove the clamp, clip and bleeder plug cap, and disconnect the pad wear indicator assembly from the inner pad.





6. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is less than the minimum, replace the pad.





7. DISCONNECT FRONT FLEXIBLE HOSE
a. Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the front flexible hose from the disc brake cylinder assembly.





8. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
a. Remove the 2 bolts and disc brake cylinder assembly from the knuckle.





9. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot from the disc brake cylinder assembly.
10. REMOVE FRONT DISC BRAKE PISTON





a. Prepare a wooden plate to hold the pistons.





b. Place the plate between the pistons and insert a pad into one side.
c. Use compressed air to remove the pistons alternately from the disc brake cylinder assembly.

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





11. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 4 piston seals from the disc brake cylinder assembly.
12. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the front disc brake bleeder plug from the disc brake cylinder assembly.





13. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 30.0 mm (1.181 inch)
Minimum thickness: 28.0 mm (1.102 inch)
If the disc thickness is less than the minimum, replace the disc.





14. REMOVE FRONT DISC
a. Put matchmarks on the front disc and the axle hub.
b. Remove the front disc.
15. INSTALL FRONT DISC
a. Align the matchmarks, and install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

16. INSPECT DISC RUNOUT





a. Tighten the disc with the 3 hub nuts.

HINT: Use SST 09330-00021 to hold the disc during measurement.

Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





b. Using a dial indicator, measure the disc runout 10 mm inside (0.39 inch) the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maximum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout. If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc.
17. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.
18. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder assembly.
19. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
b. Install the cylinder boot to the front disc brake piston.
c. Install the piston to the front disc brake cylinder assembly.

NOTICE: Do not install the piston forcibly in the disc brake cylinder.

20. INSTALL CYLINDER BOOT
a. Install the cylinder boot to the front disc brake cylinder.

NOTICE:
^ Install the boot securely to the grooves of the cylinder and piston.
^ Do not damage the cylinder boot.





21. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the caliper with the 2 new bolts.
Torque: 110 Nm (1,122 kgf-cm, 81 ft. lbs.)

NOTICE: Since the bolted portion is an aluminum knuckle, keep it clean and avoid over tightening. Pull the disc brake cylinder assembly toward the outside of the vehicle to remove any play between the pin and knuckle hole. From this position tighten bolt 1 and then 2. Always follow these directions when installing.





22. CONNECT FRONT FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

HINT: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.

23. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)





a. Right wheel: Connect the pad wear indicator to the inner pads, and install a new clip.

NOTICE: Replace the pad wear indicator with a new one only if the wire probe is worn out and there is an open circuit.

HINT: Install the clip lock securely in the grooves of the pad.





b. Apply disc brake grease to the anti squeal shims and install them to each pad.

NOTICE:
^ When replacing worn pads, the anti squeal shims must be replaced together with the pads.
^ Install each shim in the correct position and direction.
^ There should be no oil or grease on the friction surface of the pads and the disc.
c. Install the pad wear indicator to the inner pad.

NOTICE: Install the pad wear indicator in the correct position and direction.





24. INSTALL FRONT DISC BRAKE ANTI-RATTLE SPRING
25. INSTALL FRONT DISC BRAKE W/HOLE PIN
a. Install the hole pin while pushing on the front disc brake anti-rattle spring.

HINT: Right wheel: Thread the pad wear indicator wire clamp through the hole pin.

b. Install the clip.
26. FILL RESERVOIR WITH BRAKE FLUID
27. BLEED MASTER CYLINDER
SST 09023-00101
28. BLEED BRAKE LINE
29. BLEED BRAKE ACTUATOR
30. CHECK FLUID LEVEL IN RESERVOIR
31. CHECK BRAKE FLUID LEAKAGE
If fluid leaks, tighten or replace the leaking part.
32. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)