Disassembly and Assembly

DISASSEMBLY





1. Remove cylinder boot set ring and cylinder boot.
Using a screwdriver, remove the 2 cylinder boot set rings and cylinder boots from the caliper.





2. Remove piston.
a. Place a piece of cloth or similar article between the piston and the caliper.
b. Use compressed air to remove the 2 pistons from the cylinder.

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





3. Remove piston seal.
Using a screwdriver, remove the 2 piston seals from the cylinder.
4. Remove sliding pins and dust boots.





a. Remove the 2 sliding pins from the torque plate.

NOTICE: At the time of reassembly, please refer to the following item.
- Use the sliding pin with the sliding bushing for the bottom side hole.





b. Using a screwdriver and hammer, tap out the 2 dust boots.

HINT: At the time of reassembly, please refer to the following item.
- Use a 19 mm socket wrench and hammer, tap in the 2 new dust boots into the torque plate.

NOTICE: At the time of reassembly, please refer to the following item.
- Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.

INSPECTION





1. Measure pad lining thickness.
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Replace the pad if the pads thickness is at the minimum thickness or less, or if the pad has severe and uneven wear.





2. Measure disc thickness.
Using a micrometer, measure the disc thickness.
Standard thickness: 16.0 mm (0.630 inch)
Minimum thickness: 15.0 mm (0.591 inch)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scorched or is worn unevenly.

Measure Disc Runout, Using A Dial Indicator:

3. Measure disc runout.
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) away from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 inch)
If disc's runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a "On-Car" brake lathe.
4. If necessary, adjust disc runout.
a. Remove the 2 bolts and torque plate from the carrier.
b. Remove the hub nuts and the disc. Reinstall the disc in the position turned 1/5 from its original position an the high Install and torque the hub nuts.
Torque: 103 Nm (76 ft. lbs.)
c. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
d. Repeat b) and c) until the disc has been installed on the 3 remaining hub positions.
If the minimum runout recorded in b) to d) is less than 0.05 mm (0.0020 inch), install the disc in that position. If the minimum runout recorded in b) to d) is greater than 0.05 mm (0.0020 inch), replace the disc and repeat step 3.
e. Install the torque plate and torque the mounting bolts.
Torque: 104 Nm (77 ft. lbs.)

REASSEMBLY
Reassembly is in the reverse order of disassembly.





NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows.