Rear
Rear Disc Brake AssemblyREMOVAL
CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled.
1) Set the vehicle on a lift.
2) Loosen the wheel nuts.
3) Lift-up the vehicle, and then remove the wheels.
4) Disconnect the brake hose from caliper body assembly.
5) Remove the bolt securing lock pin to caliper body.
6) Raise the caliper body and move it toward vehicle center to separate it from support.
7) Remove the support from housing.
NOTE: Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.
8) Clean mud and foreign particles from the caliper body assembly and support.
CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).
INSTALLATION
1) Install the disc rotor on hub.
2) Install the support on housing.
Tightening torque: 52 Nm (5.3 kgf-m, 38.3 ft. lbs.)
3) Apply thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
4) Install the pads on support.
5) Install the caliper body on support.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
6) Replace the brake hose gaskets with new ones, and then connect the brake hose.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
CAUTION: The brake hose must be connected without any twist.
7) Bleed air from the brake system.
DISASSEMBLY
1) Remove the boot ring.
2) Remove the piston boot.
3) Place a wooden block as shown in the figure to prevent damage to the piston. Gradually supply compressed air via inlet of the brake hose to force piston out.
4) Remove the piston seal from caliper body cylinder.
CAUTION: Be careful not to scratch the inner surface of cylinder and piston seal groove.
5) Remove the lock pin sleeve and boot from caliper body.
6) Remove the guide pin boot.
14 INCH TYPE
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4) Insert the piston into cylinder.
CAUTION: Do not force piston into cylinder.
5) Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston.
Grease: NIGLUBE RX-2 (Part No. K0779GA102)
6) Install the piston boot to caliper body, and attach boot ring.
7) Apply a coat of specified grease to the guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. K0779GA102)
8) Install the guide pin boot on support.
9) Install the lock pin boot on support and insert lock pin sleeve into place.