Removal And Installation

FRONT DISC BRAKE


Removal and Installation of Brake Caliper and Disc Rotor


REMOVAL
1. Remove the front wheel and tire. Service and Repair.
2. Remove master cylinder reservoir cap.
CAUTION:
- Refill with new brake fluid.
- Do not reuse drained brake fluid.





3. Remove the union bolt then disconnect the brake hose and discard the copper washers.
CAUTION:
Discard the copper washers, do not reuse.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.





4. Remove the sliding pin bolts and remove the caliper body from the torque member.
5. Remove the brake pads, shims, shim covers and retainers from the torque member.
6. Remove the torque member bolts and remove the torque member.





7. Remove the disc rotor. If reusing the disc rotor, apply a matching mark as shown for installation.
CAUTION:
Put matching marks on the wheel hub assembly and disc rotor, if reusing the disc rotor.

INSTALLATION





1. Install the disc rotor. If reusing the disc rotor, align the matching marks as shown for installation.
CAUTION:
Align the matching marks on the wheel hub assembly and disc rotor, if reusing the disc rotor.
2. Install torque member and tighten the torque member bolts to specification. Exploded View SEE Removal and Installation of Brake Caliper and Disc Rotor, "Exploded
View of Brake Caliper".
3. Install the brake pads, shims, shim covers and retainers on the torque member. Exploded View Removal And Installation, "Exploded View of Brake Pads".





4. Install caliper body and sliding pins, then tighten the sliding pin bolts to the specified torque. Exploded View.

CAUTION:
When installing the caliper body to the torque member, wipe any oil off of the knuckle spindle, washers and caliper body attachment surfaces.





5. Install brake hose by aligning with the protrusion on caliper body, then install new copper washers and union bolt. Tighten union bolt to specified torque. Exploded View.

CAUTION:
Use new copper washers for installation.
6. Refill with new brake fluid as necessary and bleed the air. Service and Repair.

CAUTION:
- Refill with new brake fluid.
- Do not reuse drained brake fluid.
7. Install the front wheel and tire. Service and Repair.