Front

FRONT DISC BRAKE





COMPONENTS

INSPECTION





If a squeaking noise occurs from the front brake while driving and braking, inspect the brake pads.

REMOVAL (BRAKE PAD)
1. Remove the wheel and tire.





2. Check the pad thickness through the cylinder inspection hole. If the pad lining thickness is out of specification, replace the pads.





3. Remove two bolts from the torque plate and remove the brake cylinder.





4. Remove the brake cylinder and suspend it with wire.

NOTE: Do not disconnect the brake hose.





5. Remove the pads.

CAUTION: Be careful not to depress the brake pedal while disassembling the pads.

REMOVAL (CALIPER)
1. Remove the wheel and tire.





2. Remove the brake hose from the caliper.





3. Remove the caliper assembly by removing the torque plate.

DISASSEMBLY (CALIPER)





1. Loosen the caliper attaching guide bolts and separate the caliper.
2. Remove the boot ring using a flat blade screwdriver.





3. Remove the piston boot.





4. Remove the piston by applying compressed air through the brake hose fitting hole.

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





5. Using a screwdriver, remove the piston seal carefully so as not to damage the cylinder wall.
6. Clean the outer surface of the piston and the inner surface of the cylinder with the specified brake fluid.

INSPECTION (BRAKE PAD)
1. Check the pads for wear or oil contamination. Replace or correct if necessary.





2. Check the shims for damaged or deformed.

INSPECTION (CALIPER)
1. Check the caliper body cylinder inner surface for wear, damage and/or corrosion.
2. Check the piston for wear, damage and/or corrosion.
3. Check the caliper body and sleeve for wear.
4. Check pads for deformation, metal backing for damage, and for oil on the pads.
5. Check the wear indicator for damage.








6. Inspect the brake disc using a dial indicator and micrometer.
7. If necessary, replace the brake disc.
1) Jack up the vehicle and support it with jack stands.
2) Remove the wheel and tire.
3) Remove the front wheel brake assembly from the knuckle and suspend it with a wire.
4) Remove the front disc from the hub.

FRONT BRAKE DISC THICKNESS CHECK





1. Using a micrometer, measure disc thickness at eight positions, approximately 45° apart and 10 mm (0.39 inch) in from the outer edge of the disc.
Brake disc thickness
Standard value: 26.0 mm (1.024 inch)
Limit: 24.4 mm (0.96 inch)
Thickness variation (at least 8 positions)
The difference between any thickness measurements should not be more than 0.005 mm (0.0002 inch).
2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the specification, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD. DL-8700PF" or equivalent). Be sure to follow the exact brake lathe manufacturer instructions.

FRONT BRAKE DISC RUN-OUT CHECK





1. Remove the caliper support bolts, then raise the caliper assembly upward and secure by using wire.
2. Inspect the disc surface for groove, cracks, and rust. Clean the disc thoroughly and remove all rust.





3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer circumference of the brake disc, and measure the runout of the disc.
Limit: 0.03 mm (0.0012 inch)

NOTE: Tighten the nuts in order to secure the disc to the hub.

ASSEMBLY (CALIPER)
1. Clean the components with isopropyl alcohol except pad and shim.





2. Install the piston seal.
3. After applying specified brake fluid to the piston outer surface, install the piston into the cylinder





4. Install the piston boot and boot ring.





5. Install the guide pin boots and guide pin.

INSTALLATION (BRAKE PAD)
1. Install the pad clips.





2. Install the pads onto each pad clip.

NOTE:
^ All four pads must be replaced as a complete set.
^ Position the pad with its pad wear sensor upward on piston side.
^ Remove rust before position the pad clip or replace new one if it is damaged.

3. Press in piston with a hammer handle or equivalent.
4. Lower and insert the brake cylinder carefully so as not to damage the boot.





5. Install the two guide rod bolts and tighten.
Guide rod bolt: 22 - 32 Nm (220 - 320 kg-cm, 16 - 24 ft. lbs.)

INSTALLATION (CALIPER)





1. Install the pads and brake cylinder.





2. Install the brake hose to the caliper.
Bleeder screw tightening torque: 7 - 13 Nm (70 - 130 kg-cm, 5 - 9.6 ft. lbs.)
3. Fill brake reservoir with brake fluid.
4. Bleed the system.

FRONT BRAKE DISC RUN-OUT CORRECTION
1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, replace the disc and hub, and then measure the run-out again.





1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.





2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial direction and measure the play.
Limit: 0.03 mm (0.0012 inch)
If the play is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.
3) If the play does not exceed the limit specification, install the brake disc at a position 180° from the chalk mark, and then check the run-out of the brake disc once again.





2. If the run-out cannot be corrected by changing the phase of the brake disc, replace the brake disc or turn rotor with an on the car type brake lathe ("MAD, DL-8700PF" or equivalent). Be sure to follow the exact brake lathe manufacturer instructions. Rotors turned on the vehicle will often have a lower run-out than a new brake disc.