Disassembly and Assembly

DISASSEMBLY





1. REMOVE SET RINGS AND CYLINDER BOOTS
Using a screwdriver, remove the 2 set rings and 2 cylinder boots





2. REMOVE PISTONS
a. Put a piece of cloth or an equivalent between the piston and caliper
b. Use compressed air to remove the 2 pistons from the cylinder.

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





3. REMOVE PISTON SEALS FROM BRAKE CYLINDER
Using a screwdriver, remove the 2 piston seals





4. REMOVE SLIDING PINS AND DUST BOOTS
a. Remove the 2 sliding pins from the torque plate

NOTICE: At the time of reassembly, please refer to the following item. Insert the sliding pin with the sliding bushing into the bottom side.

b. Using a screwdriver and hammer, tap out the 2 dust boots

NOTICE: At the time of reassembly, please refer to the following item. Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.

HINT: At the time of reassembly, use a 21 me socket and tap in new dust boots into the torque plate.

INSPECTION





1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 inch)
Minimum thickness: 1.0 mm (0.03g inch)
Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear.





2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 32.0 mm (1.260 inch)
Minimum thickness: 30.0 mm (1.181 inch)
Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly.





3. MEASURE DISC RUNOUT
a. Temporarily fasten the disc with the 3 hub nuts.
b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) away 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.
4. IF NECESSARY, ADJUST DISC RUNOUT
a. Remove the 2 bolts and torque plate.
b. Remove the 3 hub nuts and disc. Turn the disc 1/5 turn and reinstall the disc. Install and torque the 3 hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
c. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
d. Repeat (b) until the disc has been installed on the 3 remaining hub positions.
e. If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 inch), install the disc in that position.
f. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 inch), replace the disc and repeat step 3.
g. Install the torque plate and torque the 2 bolts.
Torque: 118 Nm (1,200 kgf-cm, 87 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.