Disassembly and Assembly

DISASSEMBLY





1. REMOVE CYLINDER BOOT SET RINGS AND CYLINDER BOOT.
Using a screwdriver, remove the 4-cylinder boot set rings and cylinder boots from the caliper.

2. REMOVE PISTONS FROM CYLINDER





a. Prepare the wooden plate to hold the pistons.





b. Place the plate between the piston and insert a pad at one side.
c. Use compressed air to remove the piston alternately from the cylinder.

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





3. REMOVE PISTON SEALS FROM BRAKE CYLINDER
Using a screwdriver, remove the 4 piston 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 thickess: 1.0 mm (0.39 inch)
Replace the pad if the pad's thickness is at the minimum or if it shows signs of uneven wear.





2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness
Standard thickness: 32.0 mm (1.260 inch)
Minimum thickness: 30.0 mm (1.181 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.





3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the out side edge.
Maximum disc runout: 0.07 mm (0.0028 inch)
If the bearing play and axle hub runout are not abnormal, replace the disc or grind it on an "On-Car brake lathe".

HINT: Before measure the runout, from that the front bearing preload is within the specification.

4. IF NECESSARY, REPLACE DISC
a. Remove the front axle hub
b. Remove the disc from the axle hub
c. Install a new disc and torque the 5 bolts.
d. Install the axle hub and adjust the front bearing preload.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

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