Removal

BRAKE: FRONT BRAKE (for 2WD): 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

(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 in.)

Minimum thickness:

23.0 mm (0.906 in.)

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.