Front

FRONT DISC BRAKE


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. Service and Repair.

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. Service and Repair.

DISC ROTOR INSPECTION

Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are.

Runout Inspection





1. Fix disc rotor to wheel hub using wheel nuts (2 or more positions).
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside the disc edge.]

Runout limit: 0.035 mm (0.0014 in)
(with it attached to the vehicle)

NOTE:
Before measuring, make sure that wheel bearing axial end play is within the specification. Testing and Inspection Front Wheel Hub and Knuckle, "On-Vehicle Inspection".
3. When runout exceeds limit value, displace mounting positions of disc rotor by one hole. And then find a position of the minimum value for runout.
4. Replace or lathe disc rotor if runout is outside the limit even after performing the above operation.
[When lathing, use the Pro-Cut PFM On-Car Brake Lathe (Tool No. 38-PFM90.5) or equivalent.]

Thickness Inspection





Check thickness of the disc rotor using a micrometer. Replace disc rotor if thickness is under the wear limit.

Standard thickness: 28.0 mm (1.102 in)
Wear limit: 26.0 mm (1.024 in)
Thickness variation (Measured at 8 positions) : 0.015 mm (0.0006 in)

BRAKE BURNISHING PROCEDURE
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.

CAUTION:
- Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely fitted.
- Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.