Disassembly and Assembly

DISASSEMBLY





1. Loosen the caliper attaching guide bolts and separate the caliper.
2. Remove the boot ring using a flat blade screwdriver.





3. Remove the piston boot.
4. Remove the piston by applying compressed air through the brake hose fitting hole.





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





5. Using a screwdriver, remove the piston seal carefully so as not to damage the cylinder wall
6. Clean the outer surface of the piston and the inner surface of the cylinder with the specified brake fluid.

INSPECTION
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the carrier for damage, rust, wear and cracks.





6. Inspect the brake disc using a dial indicator and micrometer. Machine or replace as necessary.
Thickness of disc
Standard value 26 mm (1.02 inch)
Standard limit 24.4 mm (0.96 inch)
Runout of disc
Standard limit 0.05 mm (0.0020 inch)
Disc thickness variation
Standard limit 0.005 mm (0.0002 inch)

7. If necessary, replace the brake disc.
1) Jack the vehicle up and support it with jack stands.
2) Remove the wheel and tire.
3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
4) Remove the front disc from the hub.

ASSEMBLY
1. Clean the components with isopropyl alcohol except for the pad and shim.
2. Install the piston seal.





3. After applying the specified brake fluid to the piston outer surface, install the piston into the cylinder.





4. Install the piston boot and boot ring.





5. Install the guide pin boots and guide pin.