Disassembly and Assembly

FRONT BRAKE

COMPONENTS:

DISASSEMBLY
1. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 brake pads w/anti squeal shim from the cylinder mounting LH.
2. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 2 anti squeal shims from each pads.
b. Using a screwdriver, remove the pad wear indicator from the inner pad.
3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the front disc brake pad support plate (No. 1) and the front disc brake pad support plate (No. 2) from the front disc brake cylinder mounting LH.
4. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the 2 front disc brake cylinder slide pins from the front disc brake cylinder mounting LH.





5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin (lower).

NOTICE: Do not damage the front disc brake cylinder slide pin No. 2.

6. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Remove the 2 front disc brake cylinder bush dust boots from the front disc brake cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and the front disc brake cylinder mounting LH.





8. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot

NOTICE: Do not damage the inner cylinder and cylinder groove.





9. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rug between the brake piston and the disc brake cylinder sub-assembly
b. Use compressed air to remove the brake piston from the disc brake cylinder sub-assembly.

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

NOTICE: Do not spatter the brake fluid.





10. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the front disc brake cylinder sub-assembly.

NOTICE: Do not damage the inner cylinder and cylinder groove.

11. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
a. Remove the bleeder plug cap to the front disc brake bleeder plug.
12. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the front disc brake bleeder plug from the disc brake cylinder sub-assembly.





13. REMOVE FRONT DISC
a. Put matchmarks on the front disc and the axle hub.
b. Remove the front disc.

INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
a. Check the brake cylinder bore and the brake piston for rust or scoring.





2. INSPECT PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 12.7 mm (0.500 inch)
Minimum thickness: 1.0 mm (0.039 inch)
3. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Inspect the front disc brake pad support plate (No. 1) and the front disc brake pad support plate (No. 2).
(1) Make sure that it has sufficient rebound, no deformation cracks or wear, and all rust, dirt are cleaned off.

HINT: If necessary, replace the brake pad support plate.





4. INSPECT DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)

REASSEMBLY
1. INSTALL FRONT DISC
a. Align the matchmarks, install the front disc

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.





2. INSPECT DISC RUNOUT
a. Temporarily install the front disc with hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Using a dial gauge, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is greater than the maximum value, check the bearing play in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder sub-assembly.
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
a. Install the bleeder plug cap to the front disc brake bleeder plug.
5. INSTALL PISTON SEAL
a. Apply the lithium soap base glycol grease to a new piston seal.
b. Install the piston seal to the disc brake cylinder subassembly.





6. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the front disc brake piston and a new cylinder boot.
b. Install the cylinder boot to the front disc brake piston.
c. Install the piston to the front disc brake cylinder sub assembly.

NOTICE: Do not install the piston forcibly in the disc brake cylinder.





7. INSTALL CYLINDER BOOT
a. Apply lithium soap base glycol grease to a new cylinder boot. Install the cylinder boot to the front disc cylinder sub-assembly.

HINT: Install the boot securely to the grooves of the cylinder and piston.

b. Using a screwdriver, install a new set ring.

NOTICE:
^ Install the boot securely to the grooves of the cylinder and piston.
^ Do not damage the cylinder boot.

8. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the front disc brake cylinder mounting LH with the 2 bolts.
Torque: 107 Nm (1,090 kgf-cm, 79 ft. lbs.)
9. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
b. Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
10. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to the a new front disc brake cylinder slide bush.
b. Install the front disc brake cylinder slide bush to the front disc brake cylinder slide pin No. 2.
11. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply the lithium soap base glycol grease to the sliding part and the seal surface of the 2 slide pins.
b. Install the 2 front disc brake cylinder slide pins.
12. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the front disc brake pad support plate (No. 1) and the front disc brake pad support plate (No. 2) to the front disc brake cylinder mounting LH.





13. INSTALL ANTI SQUEAL SHIM KIT FRONT
a. Apply disc brake grease to the anti squeal shims and install them to each pad

NOTICE:
^ When replacing worn pads, the anti squeal shims must be replaced together with the pads.
^ Install the shims correctly of which positions and directions.

b. Install the pad wear indicator to the inner pad.

NOTICE: Install the pad wear indicator correctly of which positions and directions.

14. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the 2 brake pads w/anti squeal shim to the disc brake cylinder mounting LH

NOTICE: There should be no oil or grease on the friction surface of the pads and the disc.