Rear

Rear Disc Brake Assembly

REMOVAL

CAUTION: Do not allow brake fluid to come in contact with the vehicle body; wipe off completely if spilled.

1) Set the vehicle on the lift.
2) Loosen the wheel nuts.
3) Lift-up the vehicle and remove the wheels.
4) 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.

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

INSTALLATION
1) Install the disc rotor on hub.
2) Install the support on housing.
Tightening torque: 53 Nm (5.4 kgf-m, 39.1 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.
^ Replace the pads if there is oil or grease on them.

3) Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip.
4) Install the pads on support.
5) Install the caliper body on support.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
6) Connect the brake hose.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)

CAUTION:
^ The brake hose must be connected without any twist.
^ Replace the brake hose gaskets with new ones.

7) Bleed air from the brake system.

DISASSEMBLY





1) Remove the boot ring.





2) Remove the piston boot.





3) Gradually supply compressed air via inlet of caliper body 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.





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

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) Insert the piston into cylinder.

CAUTION: Do not force the piston into cylinder.

5) Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston.
Grease: NIGLUBE RX-2 (Part No. 003606000)





6) Install the piston boot to the caliper body, and attach boot ring.
7) Apply a coat of specified grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves.





Grease: NIGLUBE RX-2 (Part No. 003606000)
8) Install the guide pin boot on caliper body.
9) Install the lock pin boot on caliper body and insert lock pin sleeve into place.

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.