Removal and Replacement

FRONT BRAKE

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.





3. REMOVE DISC BRAKE CYLINDER ASSEMBLY
(a) Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose.





(b) Hold the disc brake cylinder slide pin and remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the 2 disc brake pads with anti-squeal shim from the disc brake cylinder mounting.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the 4 anti-squeal shims from each pad.
(b) Remove the pad wear indicator plate from each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the 2 disc brake pad support plates from the disc brake cylinder mounting.





7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the disc brake cylinder slide pin from the disc brake cylinder mounting.





8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Using a screwdriver, remove the disc brake cylinder slide bush from the disc brake cylinder slide pin (No. 2).

NOTICE: Be careful not to damage the disc brake cylinder slide pin (No. 2).





9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING
(a) Remove the 2 bolts and disc brake cylinder mounting.





10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Place soft jaws on a vise and hold the disc brake cylinder mounting in the vise through aluminum plates.
(b) Using a screwdriver and hammer, remove the 2 disc brake bush dust boots from the disc brake cylinder mounting.





11. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 inch)
Minimum thickness: 23.0 mm (0.906 inch)
If the disc thickness is less than the minimum, replace the disc.
12. REMOVE FRONT DISC
(a) Make matchmarks on the front disc and the axle hub.
(b) Remove the front disc.

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

HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout.





2. INSPECT DISC RUNOUT
(a) Provisionally fasten the disc with the hub nuts.
Torque: 113 Nm (1,152 kgf-cm, 83 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 the axle hub runout. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on an on-car brake lathe.





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





4. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
(a) Install the disc brake cylinder mounting with the 2 bolts.
Torque: 108 Nm (1,101 kgf-cm, 80 ft. lbs.)
5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply lithium soap base glycol grease to a new disc brake cylinder slide bush.
(b) Install the disc brake cylinder slide bush to the bottom side of the disc brake cylinder slide pin (No. 2).





6. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply lithium soap base glycol grease to the sliding part and the sealing surface of the disc brake cylinder slide pin.
(b) Install the disc brake cylinder slide pin onto the disc brake cylinder mounting.
7. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the 2 disc brake pad support plates onto the disc brake cylinder mounting.
8. INSTALL ANTI SQUEAL SHIM KIT FRONT

NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.

(a) Apply disc brake grease to the both surfaces of the 2 anti-squeal shims and install them.
(b) Install the 2 outside anti-squeal shims onto the brake pads.
(c) Install the pad wear indicator plate facing upward, and install each pad.
9. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Install the 2 disc brake pads with anti-squeal shim onto the disc brake cylinder mounting.

NOTICE: There should be no oil or grease on the friction surfaces of the brake pads or the front disc.





10. INSTALL DISC BRAKE CYLINDER ASSEMBLY
(a) Install the disc brake cylinder with the 2 bolts.
Torque: 36.3 Nm (370 kgf-cm, 27 ft. lbs.)





(b) Install a new gasket and flexible hose with the union bolt.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

HINT: Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

11. FILL RESERVOIR WITH BRAKE FLUID (w/ VSC)
12. FILL RESERVOIR WITH BRAKE FLUID (w/o VSC)
13. BLEED MASTER CYLINDER (w/o VSC)
14. BLEED BRAKE LINE (w/ VSC)
15. BLEED BRAKE LINE (w/o VSC)
16. CHECK FLUID LEVEL IN RESERVOIR (w/ VSC)
17. CHECK FLUID LEVEL IN RESERVOIR (w/o VSC)
18. CHECK FOR BRAKE FLUID LEAKAGE
19. INSTALL FRONT WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)