Disassembly and Assembly

WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

CAUTION:
- When cylinder body is open, do not depress brake pedal because piston will pop out.
- Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads.
- It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
- Burnish the brake contact surfaces after refinishing or replacing brake rotors, after replacing pads, or if a soft pedal occurs at very low mileage.

DISASSEMBLY





1. Remove piston boot retainer with a flat-bladed screwdriver.





2. Push out piston and piston boot with compressed air.

WARNING: Do not place your finger in front of piston.

3. Remove piston seal with a suitable tool.

CAUTION: Do not scratch or score cylinder wall.

INSPECTION AFTER DISASSEMBLY
Caliper
CYLINDER BODY

CAUTION: Use brake fluid to clean. Never use mineral oil.
- Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.

PISTON

CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of the conditions are observed.

Rotor
VISUAL INSPECTION
Check rotor for roughness, cracks or chips.

RUNOUT





1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the specifications before measuring runout.
3. Change relative positions of rotor and wheel hub so that runout is minimized.
Maximum runout: 0.07 mm (0.0028 inch)

THICKNESS





Check thickness using a micrometer.
Rotor repair limit
Standard thickness: 9 mm (0.35 inch)
Minimum thickness: 8 mm (0.31 inch)
Thickness variation (At least 8 positions) : Maximum 0.015 mm (0.0006 inch)

ASSEMBLY





1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston.
3. Secure piston boot with retainer.