Front
Front Disc Brake AssemblyREMOVAL
CAUTION:
Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.
1) Lift up the vehicle, and then remove the front wheels.
2) Remove the caliper body assembly.
(1) Remove the union bolt and caliper bolt, and remove the caliper body assembly from the support - front disc brake.
3) Remove the support - front disc brake.
NOTE:
Remove the support - front disc brake only when replacing the disc rotor or the support - front disc brake. It is not necessary to remove it when servicing the caliper body assembly.
(1) Remove the brake pad from support - front disc brake.
(2) Remove the mounting bolts, and then remove the support - front disc brake from the housing assembly - front axle.
INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly and support - front disc brake.
1) Check each part.
2) Apply a thin coat of grease to the support - front disc brake.
Grease:
Molykote M7439 (Part No. 003602001)
3) Install the support - front disc brake to the housing assembly - front axle.
Tightening torque:
Mounting bolt: 80 Nm (8.16 kgf-m, 59.0 ft-lb)
4) Apply a thin coat of grease to the pad clip. (A)
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit
5) Apply a thin coat of grease to the pad and both sides of the shim - disc brake front inner (a). (B)
Grease:
Molykote AS880N (Part No. K0777YA010) or an item contained in the pad kit
6) Install the brake pad to the support - front disc brake.
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 with a new part.
NOTE:
Install the brake pad indicator in proper direction.
7) Install the caliper body assembly to the support - front disc brake.
Tightening torque:
Caliper bolt: 27 Nm (2.75 kgf-m, 19.9 ft-lb)
8) Connect the brake hose using a new brake hose gasket.
Tightening torque:
Union bolt: 18 Nm (1.84 kgf-m, 13.3 ft-lb)
9) Bleed air from the brake system.
10) Install the front wheels.
Tightening torque:
120 Nm (12.24 kgf-m, 88.5 ft-lb)