Rear Disc Brake

REAR DISC BRAKE


Disassembly and Assembly of Brake Caliper Assembly


NOTE:
Do not remove torque member, pads, shims, shim cover, 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 cover and pad retainers from torque member.
2. Remove sliding pin boots from torque member.





3. Remove retaining ring from cylinder body using a flat-bladed screwdriver as shown in the figure.





4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove piston and piston boot.

CAUTION:
Do not get fingers caught in the piston.





5. 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 Bolt, Sliding Pin Boot
Check 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 the piston boot, and then install cylinder side lip on the piston boot securely into the 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. Secure piston boot with retaining ring.

CAUTION:
- Make sure that boot is securely engaged in the groove on cylinder body.
- Do not reuse retainer ring.
5. Install sliding pin boot to torque member.
6. Install the cylinder body to torque member, and then tighten sliding pin bolt to the specified torque. Component.

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 dial gauge. [Measured at 10 mm (0.39 in) inside disc edge.]

Runout limit (With it attached to the vehicle): 0.055 mm (0.0022 in)

NOTE:
Before measuring, make sure that wheel bearing axial end play is within the specification. Procedures Rear Wheel Hub, "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-PFM 90.5) or equivalent.]

Thickness Inspection





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

Standard thickness: 16.0 mm (0.631 in)
Wear limit: 14.0 mm (0.551 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 the vehicle on a 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.