Disassembly and Assembly

DISASSEMBLY





1. REMOVE CYLINDER BOOT SET RING AND CYLINDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylinder boot.





2. REMOVE PISTON FROM CYLINDER
a. Put a piece of cloth or equivalent between the piston and the caliper.
b. Use compressed air to remove the piston from the cylinder.

CAUTION: Do not place your fingers in front of the piston when using compressed air.





3. REMOVE PISTON SEAL FROM CYLINDER
Using a screwdriver, remove the piston seal.
4. REMOVE SLIDING PINS AND DUST BOOTS
a. Remove the 2 sliding pins from the torque plate.

NOTICE: At the time of reassembly, please refer to the following item.
Insert the sliding pin with sliding bushing into the lower part, and insert the sliding pin without sliding bushing into the upper part.





b. Using a screwdriver and hammer, tap out the 2 dust boots.

HINT: At the time of reassembly, please refer to the following item. Use a 24 mm socket and hammer, tap in the 2 new dust boots.

NOTICE: At the time of reassembly, please refer to the following item.
Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.

INSPECTION





1. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly.





2. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the disc's runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a "On-Car" brake lathe.





3. IF NECESSARY, ADJUST DISC RUNOUT
a. Remove the 2 bolts and torque plate from the knuckle.
b. Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts.
Torque: 104 Nm (1,050 kgf-cm, 77 ft. lbs.)
c. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
d. Repeat (b) and (c) until the disc has been installed on the 3 remaining hub positions.
^ If the minimum runout recorded in (b) to (d) is less than 0.05 mm (0.0020 inch), install the disc in that position.
^ If the minimum runout recorded in (b) to (d) is greater than 0.05 mm (0.0020 inch), replace the disc and repeat step 2.
e. Install the torque plate and torque the mounting bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)

REASSEMBLY
Reassembly is in the reverse order of disassembly.

HINT: Apply lithium soap base glycol grease and disc brake grease to the parts indicated by the arrows.