Removal and Installation
Component
Pad Replacement
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.
- If shims are rusted or show peeling of rubber coat, replace them with new shims.
- 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 drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
1. Remove master cylinder reservoir cap.
2. Remove wheel and tire.
3. Remove brake cable mounting bolt and lock spring.
4. Release parking brake control lever, then disconnect cable from the caliper.
5. Remove upper pin bolt.
6. Open cylinder body downward and secure with wire as shown.
Then remove pad retainers, and inner and outer shims.
Standard pad thickness: 10 mm (0.39 inch)
Pad wear limit: 2.0 mm (0.079 inch)
7. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown.
NOTE: Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
8. Adjust the piston to the right angle as shown.
9. Align the piston's concave to the pad's convex, then install the cylinder body to the torque member as shown.
Caliper Removal
WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other material.
1. Remove wheel and tire.
2. Remove brake cable mounting bolt and lock spring.
3. Release parking brake control lever, then disconnect cable from the caliper.
4. Remove torque member fixing bolts and brake hose connecting bolt.
NOTE: It is not necessary to remove brake hose connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.
5. Remove caliper assembly.
Caliper Disassembly
1. Remove piston by turning it counterclockwise with suitable commercial service tool or long nose pliers.
2. Pry off ring A from piston with suitable pliers and remove cup, adjuster, bearing, spacers, and wave washer.
3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover, spring and seat.
b. Pry off ring C, then remove key plate, push rod and rod.
c. Remove piston seal with a suitable tool.
CAUTION: Be careful not to damage cylinder body.
4. Remove return spring, toggle lever and cable guide.
Caliper Assembly
1. Insert cam with depression facing toward open end of cylinder.
2. Generously apply rubber grease to strut and push rod to make insertion easy.
3. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.
4. Install ring C with a suitable tool.
5. Install seat, spring, spring cover and ring B with snap ring pliers and a suitable press and drill.
6. Install cup in the specified direction.
7. Install cup, adjuster, bearing, spacers, washer and ring A with a suitable tool.
8. Insert piston seal into groove on cylinder body.
9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers, or suitable tool.
10. Fit toggle lever, return spring and cable guide.
11. Adjust the piston to the right angle as shown.
Caliper Installation
1. Install caliper assembly.
- As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely.
3. Install all parts and tighten all bolts.
4. Bleed air from brake system.
CAUTION:
- Refill with new brake fluid "DOT 3".
- Never reuse drained brake fluid.