Removal and Installation

Components

WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:
^ While removing cylinder body, never depress brake pedal because piston will pop out.
^ It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch brake hose.
^ Do not damage piston boot.
^ If any shim is subject to serious corrosion, replace it with a new one.
^ Always replace shims and shim covers as a set when replacing brake pads.
^ Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft pedal occurs at very low mileage.

Removal and Installation of Brake Pad
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove sliding pin bolt (one on top).
3. Suspend cylinder body with a wire, and remove pads, pad retainers, shim from torque member.

INSTALLATION
1. Apply Poly Butyl Cuprysil (PBC) grease or silicon based grease to the backside of pad and to both sides of shim, and attach inner shim and shim cover to inner pad, and attach the outer shim and outer shim cover to outer pad.
2. Install pad retainer and mount pad to torque member.
3. Push piston in so that pad is firmly attached and mount cylinder body to torque member.

NOTE: Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston.

CAUTION: By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the surface of reservoir tank.

4. Install sliding pin bolt (one on top) and tighten to the specified torque.
5. Check brake for drag.
6. Install tires to the vehicle.

Removal and Installation of Brake Caliper Assembly
REMOVAL





1. Remove tires from vehicle with power tool.
2. Drain brake fluid.
3. Remove union bolt and torque member bolts, and remove brake caliper assembly from the vehicle.
4. Remove disc rotor.

INSTALLATION

CAUTION:
^ Refill with new brake fluid "DOT 3".
^ Do not reuse drained brake fluid.

1. Install disc rotor.
2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque.

CAUTION: Before installing caliper assembly to the vehicle, wipe off oil and grease on washer seats on axle assembly and mounting surface of caliper assembly.

3. Install brake hose to caliper assembly and tighten union bolt to the specified torque.

CAUTION:
^ Do not reuse copper washer for union bolt.
^ Securely attach brake hose to protrusion on caliper assembly.

4. Refill new brake fluid and bleed air.
5. Install tires to the vehicle.