Front
FRONT DISC BRAKE ASSEMBLYREMOVAL AND INSTALLATION
Pre-removal & Post-installation Operation:
Removal Steps 1-7:
Required Special Tools:
^ MB990520: Piston Expander
INSTALLATION SERVICE POINTS
]]A[[ BRAKE HOSE INSTALLATION
1. Pass the brake hose through the hole in the body-side bracket.
2. Install the brake hose to the brake caliper.
3. Install the brake hose at the two fixing points.
4. Twist the brake hose toward the lesser torsion between the brake hose and body-side bracket as shown in the figure, and fix it to the body-side bracket with a clip.
]]B[[ BRAKE CALIPER ASSEMBLY INSTALLATION
Measure the brake drag force in the following procedure:
1. Using a spring scale, measure the hub sliding torque in the forward direction.
CAUTION: Keep grease or other soiling off the pad and brake disc friction surfaces.
2. Clean the piston, and press the piston into the cylinder using the piston expander (Special tool: MB990520).
3. Assemble the pad clip and pad to the caliper support, and tighten the guide pin to the specified torque.
Tightening torque: 44 ± 5 Nm (32 ± 4 ft-lb)
4. Start the engine, and depress the brake pedal forcibly two or three times. Then, stop the engine.
5. Turn the brake disc 10 times in the forward direction.
6. Using a spring scale, measure the hub sliding torque in the forward direction.
7. Obtain the disc brake drag force (difference between measured values of item 1 and item 6).
Standard value: 68 N (15.3 pounds) or less
8. If the brake drag force exceeds the standard value, disassemble the piston to check for fouling/rust on the piston sliding section and piston/seal deterioration, and confirm whether the slide pin slides properly.
INSPECTION
BRAKE DISC CHECK
^ Disc wear.
^ Disc run-out.
DISASSEMBLY AND ASSEMBLY
Disassembly Steps 1-15:
NOTE: Install the pad/wear indicator assembly to the inner side of the brake disc, making sure that the wear indicator is located on the top.
LUBRICATION POINTS
DISASSEMBLY SERVICE POINTS
[[A]] PISTON BOOT/PISTON REMOVAL
CAUTION: Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly.
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
[[B]] PISTON SEAL REMOVAL
CAUTION: Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
INSPECTION
^ Check the cylinder for wear, damage or rust.
^ Check the piston surface for wear, damage or rust.
^ Check the caliper body for wear.
^ Check the pad for damage or adhesion of grease, check the backing metal for damage.
BRAKE PAD WEAR CHECK
WARNING:
^ Always replace both brake pads on each wheel as a set (both front wheels or both rear wheels). Failure to do so will result in uneven braking, which may cause unreliable brake operation.
^ If there is significant difference in the thickness of the pads on the left and right sides, check the moving parts.
Measure thickness at the thinnest, most worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value.
Standard value: 10.0 mm (0.39 inch)
Limit: 2.0 mm (0.08 inch)