Disassembly and Reassembly

DISASSEMBLY
1. Remove cylinder boot set rings and boots.





Using a screwdriver, remove the 4 cylinder boot set rings and boots.
2. Remove pistons from cylinder.





a. Prepare the wooden plate to hold the pistons.
b. Place the plate between the pistons and insert a pad at one side.





c. Use compressed air to remove the pistons alternately from the cylinder.

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





3. Remove piston seals.
Using a screwdriver, remove the 4 seals from the cylinder.

INSPECTION
1. Measure pad lining thickness.





Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear.
2. Measure disc thickness.





Using a micrometer, measure the disc thickness.
Standard thickness: 22.0 mm (0.866 inch)
Minimum thickness: 20.0 mm (0.787 inch)
If the disc is scored or worn, or if its thickness is less than minimum, repair or replace the disc.
3. Measure disc runout.
a. Tighten the disc with the 3 hub nuts.
b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge.
Maximum disc runout: 0.07 mm (0.0028 inch)
If the runout is greater than maximum, replace the disc or grind it on a "On-Car" brake lathe.

HINT: Before measuring the runout, confirm that the front bearing play is within specification.

4. If necessary, adjust disc runout.
a. Remove the hub nuts and disc. Reinstall the disc 1/6 of a turn round from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
b. Repeat a) until the disc has been installed on the 4 remaining hub position.
c. If the minimum runout recorded in a) and b) is less than maximum disc runout, install the disc in that position.
d. If the minimum runout recorded in a) and b) is greater than maximum disc runout, replace the disc and repeat step 3.

REASSEMBLY
Reassembly is in the reverse order of disassembly.





NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows.