Rear Disc Brake Caliper Removal and Installation

Rear Disc Brake Caliper Removal and Installation

CAUTION: Do not allow brake fluid to get on painted surfaces. Painted surfaces will be damaged by brake fluid, flush it with water immediately if any fluid is spilled.

Removal
1. Hoist vehicle and remove rear wheel.
2. Release parking brake lever.
3. Remove clip (1).





4. Loosen brake pipe flare nut (1) using by flare nut wrench. Then remove clip (2).
5. Remove flexible hose joint bolt (3), and disconnect brake flexible hose (4) from brake caliper.





6. Remove caliper pin bolts.
7. Remove caliper from brake caliper carrier.
8. Disconnect parking brake cable (1) from lever (2) while rotating lever in direction of arrow.





9. Remove brake pads, slide pins and slide pin boots from brake caliper carrier.
10. Remove brake caliper carrier (1) from torsion beam (2).





Installation
1. Install brake caliper carrier (1) to torsion beam (2).

Tightening torque
Brake caliper carrier bolt a: 60 Nm (6.0 kgf-m, 43.5 ft. lbs.)





2. Install new slide pin boots (1) to brake caliper carrier.
3. Apply rubber grease to slide pins, then install slide pin (2) to front side and slide pin (3) to rear side of brake caliper carrier.

NOTE: Be sure not to install wrongly because the shape of slide pins are different as shown below.








4. Pass parking brake cable (1) through bracket (3) of caliper.
5. Hang parking brake cable on lever (2) as follows.

NOTE: Make sure that lever (4) contacts pin (5).





6. Install brake pads and caliper.
7. Connect flexible hose (4) with new washers (5) to caliper and brake pipe temporarily by hand. Then install clip (2).
8. Tighten flexible hose joint bolt (3) and brake pipe flare nut (1).

WARNING: Make sure that flexible hose is not twisted when tightening joint bolt. If it is twisted, reconnect it using care not to twist it.

Tightening torque
Flexible hose joint bolt a: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
Brake pipe flare nut b: 16 Nm (1.6 kgf-m, 12.0 ft. lbs.)





9. Install brake cable clip (1) securely to bracket (2).





10. After reassembling brake lines, bleed air from them.
11. Check to make sure that system is free from fluid leakage.
12. Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so as to obtain proper disc to pad clearance.
13. Check to make sure that parking brake lever stroke is as specified. If not, adjust.
14. Install rear wheel.
15. Remove vehicle from hoist and perform brake test (foot brake and parking brake).