Front

FRONT BRAKE

COMPONENTS:

DISASSEMBLY
1. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake cylinder mounting LH in the vise through aluminum plates.





(b) Using a screwdriver and hammer, remove the 2 front disc brake bush dust boots from the front disc brake cylinder mounting LH.





2. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder boot.
3. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug, between the front disc brake piston and the disc brake cylinder sub-assembly.





(b) Use compressed air to remove the front disc brake piston from the disc brake cylinder sub-assembly.

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

NOTICE: Do not spatter the brake fluid.





4. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the front disc brake cylinder sub-assembly.

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

5. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assembly.
6. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP





7. REMOVE FRONT DISC
(a) Place matchmarks on the front disc and the axle hub.
(b) Remove the front disc.

REASSEMBLY





1. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.

HINT: Select the installation position where the disc has the minimum runout.

2. 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 indicator, measure the disc runout 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 the maximum value or greater, check the bearing play in the axial direction and check for the axle hub runout. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the front disc brake cylinder sub-assembly.
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
5. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the front disc brake cylinder sub-assembly.





6. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the front disc brake piston to the front disc brake cylinder sub-assembly.

NOTICE: Do not install the piston forcibly in the front disc brake cylinder sub-assembly.





7. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the front disc brake cylinder sub-assembly.

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.





8. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake cylinder mounting LH in the vise through aluminum plates.
(b) Place front disc brake cylinder mounting LH in vise.
(c) Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
(d) Using a socket wrench (19 mm) and hammer, drive the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.