Front
Front Disc Brake AssemblyREMOVAL
CAUTION: Do not allow brake fluid to come in contact with vehicle body. If it does, wash off with water and wipe away completely.
1. Lift-up the vehicle, and remove the front wheels.
2. Remove the union bolt, and disconnect the brake hose from the caliper body assembly.
3. Remove the bolt securing the lock pin to caliper body.
4. Raise the caliper body, and then move it toward vehicle center to separate it from the support.
5. Remove the support from housing.
NOTE: Remove the support only when replacing the rotor or support. It need not be removed when servicing the caliper body assembly.
6. Remove mud and foreign matter from the caliper body assembly and support.
INSTALLATION
1. Install the support to the housing.
Tightening torque: 120 Nm (12.2 kgf-m, 88.5 ft. lbs.)
2. Apply a thin coat of Molykote M7439 to the pad clip.
3. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the contact surface between pad and inner shim.
4. Apply a thin coat of Molykote AS880N (Part No. K0779YA010) to the three contact surfaces between inner shim and outer shim of outer pads.
5. Install the pad to support.
NOTE: Install the pad indicator in proper direction.
CAUTION:
^ Be sure to install so that the pad return spring faces the input side of the direction of brake rotor rotation, as shown in the figure.
^ Correctly install the pad return spring to the supporting surface of the pad clip as shown in the figure.
^ If the pad return spring is deformed or damaged, replace the brake pad.
6. Install the caliper body to the support.
Tightening torque: 27 Nm (2.8 kgf-m, 19.9 ft. lbs.)
7. Connect the brake hose using a new brake hose gasket.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
8. Bleed air from the brake system.
DISASSEMBLY
1. Remove mud and foreign matter from the caliper body assembly and support.
CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.
2. Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
3. Gradually apply compressed air via the brake hose installation hole to push the piston out.
4. Remove the piston boot.
5. Remove the piston seal from caliper body cylinder.
CAUTION: Do not damage the cylinder and piston seal groove.
6. Remove the guide pin and boot from caliper body.
ASSEMBLY
1. Clean the inside of the caliper body using brake fluid.
2. Apply a coat of brake fluid to piston seal and install piston seal in the groove on caliper body.
3. Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4. Apply a coat of specified grease to the boot, and fit to the groove on the ends of the cylinder.
Grease: NIGLUBE RX-2 (Part No. K0779GA102)
5. Insert the piston into cylinder.
CAUTION: Do not force the piston into cylinder.
6. Position the boot in the grooves on cylinder and piston.
7. Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. K0779GA102)
8. Insert the lock pin and guide pin boot into the support.
