Front

Front Disc Brake Assembly

REMOVAL
1) Set the vehicle on the lift.
2) Loosen the wheel nuts.
3) Jack-up the vehicle, and remove the front wheel.





4) Remove the union bolt and disconnect the brake hose from caliper body assembly.





5) Remove the bolt securing lock pin to caliper body.
6) Raise the caliper body and move it toward the vehicle center to separate it from support.





7) Remove the support from housing.

NOTE: Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.

8) Clean mud and foreign particles from the caliper body assembly and support.

INSTALLATION
1) Install the support on housing.
Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.)
17 inch type:
Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft. lbs.)


CAUTION:
^ Always replace the pads for both the left and right wheels at the same time. Also replace the pad clips if they are twisted or worn.
^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad.
^ When replacing the pads, replace the pads of the right and left wheels at the same time.

2) Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip.





3) Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and inner shim. (Non-turbo model)
4) Install the pads on support. 5) Install the caliper body on support.
Tightening torque: 26.5 Nm (2.70 kgf-m, 19.5 ft. lbs.)
6) Connect the brake hose.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)

CAUTION: Replace the brake hose gaskets with new ones.

7) Bleed air from the brake system.

DISASSEMBLY
1) Clean mud and foreign particles from the caliper body assembly and support.

CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).





2) Gradually supply compressed air via inlet of the brake hose to force piston out.

CAUTION:
^ Place a wooden block as shown in the figure to prevent damage to piston.
^ Do not apply excessively high-pressure.





3) Remove the piston boot.





4) Remove the piston seal from caliper body cylinder.
5) Remove the guide pin and boot from caliper body.

ASSEMBLY
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4) Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston boot onto cylinder.
Grease: NIGLUBE RX-2 (Part No. 003606000)





5) Insert the piston into cylinder.

CAUTION: Do not force the piston into cylinder.





6) Position the boot in grooves on cylinder and piston.
7) Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. 003606000)





8) Install the lock and guide pin boot on support.

INSPECTION

NOTE: Repair or replace the faulty parts.

1) Check the caliper body and piston for uneven wear, damage or rust.
2) Check the rubber parts for damage or deterioration.