Disassembly and Assembly

DISASSEMBLY





1. REMOVE MAIN PIN BOOT
2. REMOVE 2 DUST BOOTS AND SLIDING BUSHING

NOTICE: Ensure that the boots are secured firmly to the bushing and caliper grooves.





3. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot from the caliper.
4. REMOVE PISTON
a. Place a piece of cloth or similar 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.





5. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.

INSPECTION





1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.

Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)

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: 10.0 mm (0.394 inch)
Minimum thickness: 9.0 mm (0.354 inch)

Replace the disc if the disc's thickness is at the minimum thickness. or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly




3. MEASURE DISC RUNOUT
Using a dial indicator, measure disc runout 10 mm (0.39 inch) away from the outer edge of the disc.

Maximum disc runout: 0.15 mm (0.0059 inch)

If the disc's 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 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.
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.)

Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
c. Repeat (b) until the disc has been installed on the 3 remaining hub positions.
^ If the minimum runout recorded in (b) and (c) is less than 0.15 mm (0.0059 inch), install the disc in that position.
^ If the minimum runout recorded in (b) and (c) is greater than 0.15 mm (0.0059 inch), replace the disc and repeat step 3.
d. Install the torque plate and torque the mounting bolts.

Torque: 47 Nm (475 kgf.cm, 34 ft. lbs.)

REASSEMBLY
Reassembly is in the reverse order of disassembly.





HINT: Apply lithium soap base glycol grease to the parts indicated by the arrows.