Front
FRONT DISC BRAKEBR-21 Component:
WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.
CAUTION:
^ While removing cylinder body, do not depress brake pedal because piston will pop out.
^ It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch brake hose.
^ Do not damage piston boot.
^ If any shim is subject to serious corrosion, replace it with a new one.
^ Always replace shim and shim cover as a set when replacing brake pads.
^ Keep rotor free from brake fluid.
^ Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
Disassembly and Assembly of Brake Caliper Assembly
NOTE: Do not remove torque member, pads, shims, shim covers, and pad retainers when disassembling and assembling cylinder body assembly.
DISASSEMBLY
1. Remove sliding pin bolt, and then remove cylinder body from torque member.
CAUTION: Do not drop pads, shims, shim covers and pad retainers from torque member.
2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION: Do not get fingers caught in the pistons.
4. Remove piston seal from cylinder body using a flat-bladed screwdriver.
CAUTION: Be careful not to damage a cylinder inner wall.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cylinder body.
CAUTION: Clean cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check torque member for wear, cracks, and damage. Replace if there are.
Piston
Check the piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
CAUTION: A piston sliding surface is plated. Do not polish with sandpaper.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pin, sliding pin bolt, and sliding pin boot for wear, damage, and cracks. Replace if there are.
ASSEMBLY
1. Apply polyglycol ether based lubricant to piston seal, and install them to cylinder body.
CAUTION: Do not reuse piston seal.
2. Apply rubber grease to piston boot. Cover the piston end with piston boot, and then install cylinder side lip on piston boot securely into a groove on cylinder body.
CAUTION: Do not reuse piston boot.
3. Apply brake fluid to piston. Push piston into cylinder body by hand and push piston boot piston-side lip into the piston groove.
CAUTION: Press the piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.
5. Install torque member to steering knuckle, and tighten mounting bolts to the specified torque. Refer to "Component".
CAUTION: Do not allow oil or any moisture on all contact surfaces between steering knuckle and brake caliper assembly.
6. Press in piston until pads can be installed, and then install cylinder body to torque member.
7. Tighten sliding pin bolts to the specified torque. Refer to "Component".