Disc Brake System: Service and Repair

FRONT BRAKE
OVERHAUL

HINT: Overhaul the RH side using the same procedures as those for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces.

3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSY





a. Remove the union bolt and the gasket from the front disc brake cylinder sub-assy, then disconnect the flexible hose.





b. Hold the front disc brake cylinder slide pin, and remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the brake pad w/ anti squeal shims.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the anti squeal shim No.1 and the anti squeal No.2 from the each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the 2 front disc brake pad support plates from the front disc brake cylinder mounting.





7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the 2 front disc brake cylinder slide pins from the front disc brake cylinder mounting.





8. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Remove the 2 front disc brake dust boots from the front disc brake cylinder mounting.





9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING
a. Remove the 2 bolts and the front disc brake cylinder mounting.





10. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the set ring and the cylinder boot.





11. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rag between the front disc brake piston and the front disc brake cylinder.
b. Use compressed air to remove the front disc brake piston from the front disc brake cylinder sub-assy.

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

NOTICE: Be careful not to spatter the brake fluid.





12. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the front disc brake cylinder.

NOTICE: Do not damage the inner cylinder and cylinder groove.

13. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the bleeder plug cap and the front disc brake bleeder plug from the front disc brake cylinder sub-assy.
14. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and the front disc brake piston for rust or scoring.





15. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.039 inch)
16. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Inspect the 2 front disc brake pad support plates. Make sure that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign matters cleaned off.





17. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 22.0 mm (0.866 inch)
Minimum thickness: 20.0 mm (0.787 inch)





18. REMOVE FRONT DISC
a. Place matchmarks on the disc and the axle hub.
b. Remove the disc.
19. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.





20. INSPECT DISC RUNOUT
a. Temporarily fasten the disc with the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial gauge, measure the disc runout at 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is maximum value or greater, check the bearing play in the axial direction and the axle hub runout. If the bearing play and the axle hub runout are not abnormal, adjust the disc runout or grind it on a"On-car" brake lathe.
21. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily install the front disc brake bleeder plug to the front disc brake cylinder.
b. Install the bleeder plug cap to the bleeder plug.
22. INSTALL PISTON SEAL
a. Apply the lithium soap base glycol grease to a new piston seal.
b. Install the piston seal on the front disc brake cylinder.





23. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
b. Install the cylinder boot to the front disc brake piston.
c. Install the piston to the front disc brake cylinder.

NOTICE: Do not install the piston to the disc brake cylinder forcibly.





24. INSTALL CYLINDER BOOT
a. Install a new cylinder boot to the front disc brake cylinder sub-assy.

NOTICE: Install the boot securely to the grooves of the cylinder and piston.

b. Using a screwdriver, install the set ring.

NOTICE: Do not damage the cylinder boot.





25. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
a. Install the front disc brake cylinder mounting with the 2 bolts.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)





26. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to the sealing surface of 2 new dust boots.
b. Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting.





27. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the sealing surface of the 2 front disc brake cylinder slide pins.
b. Install the 2 front disc brake cylinder slide pins on the front disc brake cylinder mounting.
28. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the 2 front disc brake pad support plates to the front disc brake cylinder mounting.





29. INSTALL ANTI SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to both sides of each anti squeal shim No.1.
b. Install the anti squeal shims on each pad.
30. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)

NOTICE: If necessary, replace the anti squeal shim kit when replacing the brake pad.

a. Install the disc brake pad kit to the front disc brake cylinder mounting.

NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads and the disc.

31. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY





a. Install the front disc brake cylinder sub-assy with the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)





b. Install a new gasket and the flexible hose with the union bolt.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: Install the flexible hose lock securely in the lock hole in the disc brake cylinder sub-assy.

32. FILL RESERVOIR WITH BRAKE FLUID
33. BLEED MASTER CYLINDER
SST 09023-00100
34. BLEED BRAKE LINE
35. CHECK FLUID LEVEL IN RESERVOIR
36. CHECK FOR BRAKE FLUID LEAKAGE
37. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)