Front

FRONT BRAKE CALIPER
REMOVAL





1. DISCONNECT FLEXIBLE HOSE
a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper.
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: At the time of installation, please refer to the following items.
^ Use 2 new gaskets.
^ Install the flexible hose lock securely in the lock hole in the caliper.

b. Use a container to catch the brake fluid as it drains out.
2. REMOVE CALIPER
a. Hold the sliding pin and loosen the 2 installation bolts.
Torque: 26 Nm (270 kgf-cm, 20 ft. lbs.)
b. Remove the 2 installation bolts.
c. Remove the caliper from the torque plate.
3. REMOVE 2 BRAKE PADS WITH ANTI-SQUEAL SHIMS AND 4 PAD SUPPORT PLATES

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
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
Using a screwdriver, remove the piston seal.
4. REMOVE SLIDING PINS AND DUST BOOTS
a. Remove the 2 sliding pins from the torque plate.
b. Remove the 2 dust boots.

INSPECTION





1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thickness or less, or if the pad has severe and uneven wear.





2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 in.)
Minimum thickness: 23.0 mm (0.906 in.)
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 in.) from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 in.)
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.





4. 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 in the position turned 1/5 from its original position on the hub. Install and torque the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 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 is installed on the 3 remaining hub positions.
^ If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position.
^ If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3.
e. Install the torque plate and torque the mounting bolts.
Torque: 106 Nm (1,090 kgf-cm, 78 ft. lbs.)

REASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTICE: Before reassembly, apply lithium soap base glycol grease to the parts indicated by the arrows.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After Installation, fill the brake reservoir with the fluid and bleed the brake system. Check for fluid leaks.