Brake Pad: Service and Repair

REAR DISC BRAKE





COMPONENTS





LUBRICATION POINTS

REMOVAL
1. Remove the wheel.





2. Remove the guide bolt, lift up the caliper assembly, and remove the pad assembly.

DISASSEMBLY
Rear disc brakes should be disassembled separately as a set of left and right.





1. Remove the piston boot/piston. Wrap the caliper body with a rag. Blow compressed air into the brake hose, opening and remove the piston and the piston boat.

CAUTION: Blow air slowly.

2. Remove the piston seal.
1) Remove the piston seal with your finger.

CAUTION: Do not use a screwdriver or another tool in order to avoid damage Inside the cylinder.





2) Clean the piston surface and the inside of the cylinder using alcohol or the specified brake fluid.
Brake fluid: DOT 3 or DOT 4

INSPECTION
1. Check the cylinder for wear, damage and rust.
2. Check the piston surface for wear, damage and rust.
3. Check the caliper body and sleeve for wear.
4. Check that grease is applied, and the pad and backing metal are damaged.

PAD





1. Check the pads for wear or oil contamination and replace if necessary.

NOTE: The pads for the right and left wheels should be replaced at the same time.

2. Check for worn or damaged dust boots. If dust or mud had entered the caliper assembly through this seal, the caliper assembly must be replaced or rebuilt.

CALIPER
1. Check the piston and its inside for wear, damage and rust. Replace the damaged parts if necessary.





2. Check the piston seal, boot, and pin insulators for wear and damage.

DISC





Check the disc for wear or damage and replace if necessary.

REASSEMBLY
1. When disassembling the caliper assembly, use a new piston seal and boot.





2. Apply the recommended fluid to the bearing part of the piston seal and piston. Insert the piston seal into grooves inside the caliper, being careful not to twist the seal.





3. Install the piston boot to the piston.
Confirm that the concave part of the piston is situated outward and the boot fits in grooves of the piston well.





4. Install the piston and boot in the caliper housing. Insert the boot flange in the caliper housing and check that the boot fits in grooves around the piston.
5. Apply the recommended oil to the inset the locating pin insulator.

INSTALLATION
1. Before replacing the brake pads, drain brake fluid from the master cylinder reservoir until it is had full.
2. Install two caliper guide rods and tighten to the specified torque.
Specified torque: 22 - 32 Nm (220 - 320 kgf-cm, 16.2 - 23.6 ft. lbs.)
3. After filling the master cylinder reservoir with the fluid, bleed the brake line.
Recommended brake fluid: DOT 3, DOT 4
4. Perform a road test.

NOTE: If there is a small quantity of air in the brake line, it can affect the brake pedal stroke so you must bleed the system careful.

CAUTION: When replacing the piston seal, check the pedal stroke. If the pedal stroke is too great, the piston may not retain the piston seat.
Adjust as 10110ws:
1. After removing the pad from the piston, push the piston Into the cylinder 3-5mm. Put a lever or steel plate between the piston and disc, being careful not to damage the contact surface of the disc or the piston end.
2. Install the pad Restore the brake pedal to the original position and step on it 2-3 times.
3. Repeat the above procedure more than 5 times and move the piston outward and inward to assure that the piston seal is properly installed.
4. Before driving a vehicle, step on the brake pedal and release it many times.
5. Perform the road toss.