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Disc Brake System: Service and Repair

FRONT BRAKE (2WD)





COMPONENTS

OVERHAUL

HINT: The overhaul procedure for the RH side is the same as that for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID

NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.





3. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH
a. Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose.





b. Hold the disc brake cylinder slide pin and remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Remove the 2 disc brake pads with anti-squeal shim from the disc brake cylinder mounting.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
a. Remove the 4 anti-squeal shims from each pad.
b. Remove the pad wear indicator plate from each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
a. Remove the 2 disc brake pad support plates from the disc brake cylinder mounting.





7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Remove the disc brake cylinder slide pin from the disc brake cylinder mounting.





8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Using a screwdriver, remove the disc brake cylinder slide bush from the disc brake cylinder slide pin (No.2).

NOTICE: Be careful not to damage the disc brake cylinder slide pin (No.2).





9. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Remove the 2 bolts and disc brake cylinder mounting.





10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
a. Place soft jaws on a vise and hold the disc brake cylinder mounting in the vise through aluminum plates.
b. Using a screwdriver and hammer, remove the 2 disc brake bush dust boots from the disc brake cylinder mounting.





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





12. REMOVE FRONT DISC BRAKE PISTON
a. Place a shop rag or equivalent between the disc brake piston and disc brake cylinder.
b. Use compressed air to remove the disc brake piston from the disc brake cylinder.

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

NOTICE: Be careful not to spatter the brake fluid.





13. REMOVE PISTON SEAL
a. Using a screwdriver, remove the piston seal from the front disc brake cylinder.

NOTICE: Be careful not to damage the inner cylinder or cylinder groove.

14. REMOVE FRONT DISC BRAKE BLEEDER PLUG
15. INSPECT BRAKE CYLINDER AND PISTON
a. Check the cylinder bore and disc brake piston for rust and scoring. If necessary, replace the disc brake cylinder.





16. CHECK PAD LINING THICKNESS
a. Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 1.0 mm (0.039 inch)
If the pad lining thickness is less than to the minimum thickness, replace the brake pad kit front.
17. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
a. Make sure that both plates have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off.
If necessary, replace the brake pad support plate.





18. CHECK DISC THICKNESS
a. Using a micrometer, measure the disc thickness.
Standard thickness: 25.0 mm (0.984 inch)
Minimum thickness: 23.0 mm (0.906 inch)
If the disc thickness is less than the minimum, replace the disc.
19. REMOVE FRONT DISC
a. Make matchmarks on the front disc and the axle hub.
b. Remove the front disc.
20. INSTALL FRONT DISC
a. Aligning the matchmarks, install the front disc.

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





21. INSPECT DISC RUNOUT
a. Provisionally fasten the disc with the hub nuts.
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
b. Using a dial indicator, measure the disc runout 10 mm (0.39 inch) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 inch)
c. If the disc runout is 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 normal, adjust the disc runout or grind it on an on-car brake lathe.
22. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Provisionally tighten the bleeder plug to the disc brake cylinder.
23. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to a new piston seal.
b. Install the piston seal onto the disc brake cylinder.





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

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





25. INSTALL CYLINDER BOOT
a. Install the cylinder boot onto the disc brake cylinder.

HINT: Install the cylinder boot securely into the grooves of the disc brake cylinder and piston.





26. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
a. Place soft jaws on a vise and hold the disc brake cylinder mounting in the vise through aluminum plates.
b. Apply lithium soap base glycol grease to the sealing surface of 2 new front disc brake bush dust boots.
c. Using a socket wrench (19 mm) and hammer, tap the 2 disc brake bush dust boots into the disc brake cylinder mounting.





27. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH
a. Install the disc brake cylinder mounting with the 2 bolts.
Torque: 108 Nm (1,101 kgf-cm, 80 ft. lbs.)
28. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
a. Apply lithium soap base glycol grease to a new disc brake cylinder slide bush.
b. Install the disc brake cylinder slide bush to the bottom side of the disc brake cylinder slide pin (No.2).





29. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
a. Apply lithium soap base glycol grease to the sliding part and the sealing surface of the disc brake cylinder slide pin.
b. Install the disc brake cylinder slide pin onto the disc brake cylinder mounting.
30. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
a. Install the 2 disc brake pad support plates onto the disc brake cylinder mounting.
31. INSTALL ANTI SQUEAL SHIM KIT FRONT

NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad.

a. Apply disc brake grease to the both surfaces of the 2 anti-squeal shims and install them.
b. Install the 2 outside anti-squeal shims onto the brake pads.
c. Install the pad wear indicator plate facing upward, and install each pad.
32. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
a. Install the 2 disc brake pads with anti-squeal shim onto the disc brake cylinder mounting.

NOTICE: There should be no oil or grease on the friction surfaces of the brake pads or the front disc.





33. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the disc brake cylinder with the 2 bolts.
Torque: 36.3 Nm (370 kgf-cm, 27 ft. lbs.)





b. Install a new gasket and flexible hose with the union bolt.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

HINT: Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

34. FILL RESERVOIR WITH BRAKE FLUID (W/VSC)
35. FILL RESERVOIR WITH BRAKE FLUID (W/O VSC)
36. BLEED MASTER CYLINDER (W/O VSC)
SST 09023-00101
37. BLEED BRAKE LINE (W/VSC)
38. BLEED BRAKE LINE (W/O VSC)
39. CHECK FLUID LEVEL IN RESERVOIR (W/ VSC)
40. CHECK FLUID LEVEL IN RESERVOIR (W/O VSC)
41. CHECK FOR BRAKE FLUID LEAKAGE
42. INSTALL FRONT WHEEL
Torque: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
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