Disassembly and Assembly

Front:

DISASSEMBLY





1. REMOVE CYLINDER BOOTS
Using a screwdriver, remove the cylinder boots from the cylinder.
2. REMOVE PISTONS





a. Prepare a wooden plate to hold the pistons.





b. Place the plate between the pistons and insert a pad on one side.
c. Use compressed air to remove the pistons alternately from the cylinder.

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





3. REMOVE PISTON SEALS
Using a screwdriver, remove the 4 piston seals from the cylinder.

INSPECTION





1. INSPECT 4 RETAINERS AND 2 PLATES
The retainers and plates are non-reusable part, replace the caliper if they are cracked or deformed, or if they come off.





2. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Replace the pad if the pad's thickness is at the minimum or less, or if the pad has severe, uneven wear.
3. RIGHT WHEEL:
INSPECT PAD WEAR INDICATOR





a. Disconnect the pad wear indicator connector from the speed sensor wire harness.





b. Check that continuity exists of pad wear indicator connector. If no continuity exists, replace the pad wear indicator.
c. Connect the connector to the speed sensor wire harness until the clicking sound can be heard.





4. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.02 inch)
Minimum thickness: 26.0 mm (1.024 inch)
Replace the disc if the thickness of the disc is at the minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.

5. MEASURE DISC RUNOUT





a. Tighten the disc with the 3 hub nuts.

HINT: Using SST 09330-00021 to hold the disc during measurement.

Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)





b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the out side edge.
Maximum disc runout: 0.05 mm (0.0020 inch)
If the disc's runout is 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.
6. IF NECESSARY, ADJUST DISC RUNOUT
a. Remove the 3 hub nuts, 2 screws and disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the 3 hub nuts.
Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.

HINT: Use SST 09330-00021 to hold the disc during loosening/torching the hub nuts.

Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Repeat (a) until the disc has been installed on the 3 remaining hub position.
c. If the minimum runout recorded in (a) and (b) is less than 0.05 mm (0.0020 inch), install the disc in that position.
d. If the minimum runout recorded in (a) and (b) is greater than 0.05 mm (0.0020 inch), replace the disc and repeat step 5.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

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