Brake Rotor/Disc: Service and Repair

Front Axle Hub And Steering Knuckle:

Front Axle Hub
DISASSEMBLY OF FRONT AXLE HUB

1. REMOVE DISC BRAKE CYLINDER
(a) Using SST, disconnect the brake tube from the disc brake cylinder. SST09751-36011
(b) Drain the brake fluid into a container.

c) Remove the disc brake cylinder from the steering knuckle.

2. (4WD w/FREE WHEELING HUB) REMOVE FREE WHEELING HUB

3. (4WD W/O FREE WHEELING HUB) REMOVE FLANGE
(a) Remove the cap from the flange.
(b) Remove the bolt.

(e) Install and tighten the two bolts, and remove the flange.

4. (2WD)
REMOVE HUB GREASE CAP
Remove the bolts and hub grease cap from the axle hub.

5. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.

(b) Using SST, remove the lock nut and lock washer. SST 09607-60020
(c) Using SST, remove the adjusting nut. SST 09607-60020

(d) Remove the hub and disc together with the outer bearing and thrust washer.

6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
(b) Remove the inner bearing from the hub.

INSPECTION AND REPAIR OF FRONT AXLE HUB
1. INSPECT BEARINGS
Clean the bearings and outer races and inspect them for wear or damage.
2. REPLACE BEARING OUTER RACES

(a) Using a brass bar and hammer, drive out the bearing outer race.

(b) Using SST,carefully drive in a new bearing outer race. SST 09608-35014
Outside race (09608-06020, 09608-06200) Inside race (09608-06020, 09608-06210)

3. REPLACE HUB BOLTS
(a) Place matchmarks on the axle hub and rotor disc.
(b) Remove the six bolts and rotor disc from the axle hub.
(c) Install the nut to the hub bolt.
(d) Using an extension bar and press, press out the hub bolt.

(e) Using an extension bar and press, press in the hub bolt.
(f) Align the matchmarks on the axle hub and rotor disc.
(g) Install and torque the six bolts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)

ASSEMBLY OF FRONT AXLE HUB
1. PACK BEARING WITH MP GREASE
(a) Place MP grease in the palm of your hand.
(b) Pack grease into the bearing, continuing until the grease oozes out from the other side.
(c) Do the same around the bearing circumference.

2. COAT INSIDE OF HUB WITH MP GREASE

3. INSTALL INNER BEARING AND OIL SEAL
(a) Place the inner bearing into the hub.
(b) Using SST, drive in a new oil seal into the hub. SST 09608-35014 (09608-06020, 09608-06150)
(c) Coat the oil seal lip with MP grease.

4. INSTALL AXLE HUB TO STEERING KNUCKLE
(a) Install the axle hub to the steering knuckle.
(b) Install the outer bearing.
(c) Install the thrust washer.

5. ADJUST PRELOAD
(a) Using SST, torque the adjusting nut. SST 09607-60020
Torque: 59 N.m (600 kgf.cm, 43 ft.lbf)
(b) Turn the hub right and left two or three times.
(c) Loosen the nut until it can be turned by hand.
(d) Using SST, retighten the adjusting nut. SST 09607-60020
Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

(e) Using a spring tension gauge, check the preload.
Preload (starting): 28 - 56 N (2.9 - 5.7 kgf, 6.4 - 12.6 lbf)

6. INSTALL LOCK WASHER AND LOCK NUT
(a) Install a new lock washer and the lock nut.
(b) Using SST, torque the lock nut. SST 09607-60020
Torque: 47 N.m (480 kgf.cm, 35 ft.lbf)
(c) Check that the bearing has no play.

(d) Using a spring tension gauge, recheck the preload.
Preload (starting): 28 - 56 N (2.9 - 5.7 kgf, 6.4 - 12.6 lbf)
If not within specification, adjust with the adjusting nut.

(e) Secure the lock nut by bending one of the lock washer teeth inward and an other one outward.
7. (4WD w/ FREE WHEELING HUB) INSTALL FREE WHEELING HUB

8. (4WD w/o FREE WHEELING HUB) INSTALL FLANGE
(a) Place a new gasket in position on the axle hub.
(b) Install the flange to the axle hub.
(c) Install six cone washers, plate washers and nuts. Torque the nuts.
Torque: 31 N.m (315 kgf.cm, 23 ft.lbf)
(d) Install the bolt and cap.

9. (2WD)
INSTALL HUB GREASE CAP
(a) Place a new gasket in position on the axle hub.
(b) Install the hub grease cap to axle hub with the six bolts.
Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)

10. INSTALL DISC BRAKE CYLINDER
(a) Install the disc brake cylinder to the steering knuckle and torque the bolts.
Torque: 123 N.m (1,250 kgf.cm, 90 ft.lbf)

(b) Using SST, connect the brake tube. SST 09751-36011
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
11. BLEED BRAKE SYSTEM Brake Bleeding