Disassembly and Assembly

DISASSEMBLY





1. REMOVE SET RINGS AND BOOTS
Using a screwdriver, remove the 2 set rings and 2 boots.
2. REMOVE PISTONS FROM CYLINDER





a. Prepare a wooden plate to hold the pistons.
b. Place the plate between the pistons and insert a pad on one side.





c. Use compressed air to remove the pistons alternately from the caliper.

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





3. REMOVE PISTON SEALS
Using a screwdriver, remove the 2 piston seals from the caliper.

INSPECTION





1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.5 mm (0.413 inch)
Minimum thickness: 1.0 mm (0,,039 inch)
Replace the pads if the thickness is less than the minimum or if it shows signs of uneven wear.





2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 10.5 mm (0.413 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 badly scored or worn unevenly.





3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10 mm (0.394 inch) away from the out side edge.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the disc's runout is 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 BURNOUT
a. Remove the 3 hub nuts and disc. Turn the disc 1/5 and reinstall the disc. Install and torque the 3 hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
c. Repeat (b) until the disc has been installed on the 3 remaining hub positions.
d. If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 inch), install the disc in that position.
e. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 inch), replace the disc and repeat step 3.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

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