Brake Caliper: Service and Repair

DISASSEMBLY

1. Remove the wheel and tire.
2. Disconnect the brake hose.

NOTE: Plug the brake hose, not allow brake fluid to run out.





3. Remove the cylinder mounting bolt.
4. Remove cylinder and pads.
5. Remove the caliper mounting bolts (2EA) from knuckle.
6. Remove the carrier.

INSPECTION
1. Check the caliper for wear, damage, cracks and rust.
2. Check the piston for rust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and rust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, rust, wear and cracks.

CAUTION:
1. Do not use sand paper on the piston surface.
2. All rubber parts must be replaced with new parts.








6. Inspect the disc using a caliper and dial gauge.
7. If necessary, replace the brake disc.
1. Remove the hub caps.
2. Remove the drive shaft nut.
3. Jack up the vehicle and support it with jack stands.
4. Remove the wheel and tire.
5. Remove the front wheel brake assembly from the knuckle and suspend it with a wire.



6. Disconnect the lower arm ball joint from the knuckle using the Special Tool (09568-31000)





7. Disconnect the tie rod end ball joint from the knuckle using the Special Tool (09568-31000).





8. Disconnect the drive shaft from the hub using the special tool (09526-11001).





9. Remove the hub and knuckle as an assembly from the strut.
10. Remove the disc mounting bolts. (4EA).





11. Install the special tools as illustrated.
12. Remove the hub from knuckle by turning the special tool.

CAUTION:
1. Be sure to use the special tool.
2. If the hub and knuckle are disassembled by striking with a hammer, the bearing will be damaged.

13. Replace the brake disc with new one.
14. Apply the specified multipurpose grease to the bearings and inside surface of the hub.
15. Remove inner oil seal.





16. Tighten the hub to the knuckle to 230 Nm (2,350 kg.cm, 167 ft. lbs.) with the Special Tool (09517-21500).
17. Rotate the hub to seat the bearing.
18. Measure the hub bearing starting torque.

Tightening torque:
Limit 1.3 Nm (13 kg.cm, 11 inch, lbs.)





19. If the starting torque is 0 Nm (0 inch. lbs.), measure the hub bearing axial play.





20. If the hub axial play exceeds the limit while the nut is tightened to 230 Nm (2,350 kg.cm, 167 ft. lbs.), the bearing hub and knuckle have not been installed correctly. Repeat the disassembly and assembly procedure.

Limit: Hub bearing axial play 0.11 mm (O.0043 inch) or less

21. Remove the Special Tool.
22. Apply the specified multipurpose grease to the bearing and to the inside of the knuckle.

Recommended grease: Multipurpose grease SAE J310, NLGI No.2

23. Drive the oil seal (drive shaft side) into the knuckle until it contacts the bearing outer race using Special Tools.
24. Apply the specified multipurpose grease to the lip of the oil seal.





25. Install front wheel brake assembly, hub and knuckle to the specified torque.

REASSEMBLY

1. Clean all components with isopropyl alcohol except the pads and shim.





2. Apply rubber grease to the piston seal and install the piston seal in the cylinder.





3. Assemble the piston and piston boots according to the following procedure.
1. Apply rubber grease to the caliper bore, outside surface of the piston and piston boot.
2. Install the piston boot on the piston as illustrated.
3. Insert the piston boot in the inner groove of caliper and slide the piston into the caliper.





4. Assemble the sliding parts according to the following procedure.
1. Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot and sleeve boot.





2. Insert the boots into the groove of the caliper.
5. Install the pads.

NOTE: Do not apply grease to the disc or pads.





6. Tighten the brake hose connecting bolt.

Tightening torque:
Sliding pin 34-44 Nm (350-450 kg.cm, 26-33 ft. lbs.)
Sliding bolt 22-31 Nm (220-320 kg. cm, 16-23 ft. lbs.)
Carrier mounting bolt 64-74 Nm (650-750 kg.cm, 4854 ft.lbs.)
Brake hose oil mounting bolt 25-29 Nm (250-300 kg. cm, 18-22 ft. lbs)

NOTE:
1. Check that the surface of the pin and bolts are not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting parts.