FRONT BRAKE (DISC) REMOVAL/INSTALLATION [4X2 (HIGH CLEARANCE MODEL), 4x4]

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Caution

•  Performing the following procedures without first removing the ABS wheel‐speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel‐speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.

1.  Remove in the order indicated in the table.

2.  Install in the reverse order of removal.

3.  After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

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1	Brake hose
2	Caliper
3	Guide pin
4	Disc pad (See Disc Pad Installation Note)
5	Outer shim (cover shim) (See Outer Shim, Inner Shim Installation Note)
6	Outer shim (rubber coated shim) (See Outer Shim, Inner Shim Installation Note)
7	Inner shim (cover shim) (See Outer Shim, Inner Shim Installation Note)
8	Inner shim (rubber coated shim) (See Outer Shim, Inner Shim Installation Note)
9	Guide plate (See Guide Plate Removal Note)
10	Mounting support
11	Dust boot
12	Disc plate (See Disc Plate Removal Note) (See Disc Plate Installation Note)

Guide Plate Removal Note

1.  Pull up and at a slant on the supporting part of the guide plate in the direction indicated by the arrow (1) and (2) as shown in the figure, to remove the guide plate from the mounting support.

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Caution

•  If the guide plate is removed by pulling in the direction indicated by the arrow as shown in the figure, the stopper may be deformed and not able to be reused. Do not remove in this manner.

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Disc Plate Removal Note

1.  Mark the wheel hub bolt and disc plate before removal for reference during installation.

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Disc Plate Installation Note

1.  Remove any rust or grime on the contact face of the disc plate and wheel hub.

2.  Install the disc plate and align the marks made before removal.

Outer Shim, Inner Shim Installation Note

1.  Assemble the rubber coated shim to the back plate of the disc pad.

2.  Apply brake grease to the rubber coated shim as shown in the figure.

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3.  Assemble the cover-shim to the grease-applied rubber coated shim.

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Caution

•  Be careful not to get any grease on the pad lining surface.

Disc Pad Installation Note

1.  Push the piston fully inward using the SST.

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2.  Install the disc pad.