Rear Disc Brake Service

Rear Brake Caliper:

BRAKE PADS, REPLACE

CAUTION:
With this procedure brake fluid is pushed into reservoir. To prevent overflowing, siphon some fluid out with an appliance which is used for this purpose only.

1. Raise and support vehicle, then remove wheel and tire assembly.

Rear Brake Caliper Guide Pin:

2. While holding guide pin head with an open end wrench, remove caliper upper and lower mounting bolts.
3. Lift caliper assembly upward from rotor and secure to frame with wire. It is not necessary to disconnect brake hose when replacing pads.
4. Remove brake pads from holder.

Rear Brake Caliper:

5. Using an Allen wrench, turn caliper piston clockwise and push firmly into caliper bore.

Rear Brake Caliper and Carrier:

6. Install brake pads onto holder, then install caliper over rotor.
7. Install caliper attaching bolts and torque to 35 Nm (26 ft lbs). When tightening caliper attaching bolts, use an open end wrench to hold guide pin head in position.
8. Upon reassembly after heat protection plate replacement, depress brake pedal firmly several times while vehicle is stationary to permit piston and brake pads to adjust to disc.
9. Fill brake fluid reservoir only to MAX mark. Recheck after road test.
10. After installing new brake pads, check basic setting of rear brake. Go to Parking Brake system, Adjustments for Rear Brake Basic Setting.

NOTE:
Disconnect brake hoses only when replacing or servicing calipers. When detaching but not removing brake calipers, do not remove hoses. Hang calipers on frame.

CALIPER OVERHAUL

CAUTION:
When re-using brake pads, mark to prevent changing inside to outside or from one caliper to another. Mixed pads can cause uneven braking.

Fig. 9 Rear caliper assembly.:

1. Remove parking brake lever housing.

Rear Brake Caliper:

2. Unscrew caliper piston counter clockwise and remove from caliper.

Fig. 2 Piston Seal, Removing:

3. Remove piston seal using plastic rod, being careful to avoid damage to piston or bore.

NOTE:
If either piston or bore in caliper are corroded, pitted or scored, affected part(s) must be replaced.





4. Slide outer lip onto piston.

Piston, Installing:

5. Install replacement piston seal into caliper bore. Lubricate seal with clean brake fluid.





6. Lubricate piston and caliper bore with clean brake fluid, then press piston down while screwing into bore as far as possible.
7. Position caliper with bleeder screw facing upward, then connect bleeder hose and open bleeder screw. Fill caliper with clean brake fluid through bleeder screw, then close bleeder valve.
8. After installing caliper on vehicle, bleed brake system before road testing.