Front

FRONT BRAKE (for 2GR-FSE)

COMPONENTS:

REMOVAL

HINT:
^ Use the same procedures for the RH side and LH side.
^ The procedures listed below are for the LH side.

1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
a. Draw out fluid with a syringe.

NOTICE: If brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.





3. REMOVE FRONT DISC BRAKE WITH HOLE PIN
a. Remove the clip.
b. Remove the front disc brake anti-rattle with hole pin while pushing on the anti-rattle spring.
4. REMOVE FRONT DISC BRAKE ANTI-RATTLE SPRING

NOTICE: The anti-rattle spring and clip can be used again if they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

5. REMOVE DISC BRAKE PAD AND ANTI-SQUEAL SHIMS
a. Remove the 2 pads and the 2 anti-squeal shims from each pad.






6. DISCONNECT FRONT FLEXIBLE HOSE
a. Remove the union bolt and gasket from the disc brake cylinder assembly, then disconnect the front flexible hose from the disc brake cylinder assembly.





7. REMOVE DISC BRAKE CYLINDER ASSEMBLY
a. Remove the 2 bolts and disc brake cylinder assembly from the knuckle.

DISASSEMBLY





1. REMOVE CYLINDER BOOT
a. Using a screwdriver, remove the cylinder boot from the disc brake cylinder assembly.
2. REMOVE FRONT BRAKE PISTON





a. Prepare a wooden plate to hold the pistons.





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

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





3. REMOVE PISTON SEAL
a. Using a screwdriver, remove the 4 piston seals from the disc brake cylinder assembly.
4. REMOVE FRONT DISC BRAKE BLEEDER PLUG
a. Remove the front disc brake bleeder plug from the disc brake cylinder assembly.





5. REMOVE FRONT DISC LH
a. Put matchmarks on the front disc and the axle hub.
b. Remove the front disc.

REASSEMBLY
1. INSTALL FRONT DISC LH
a. Align the matchmarks, and install the front disc.

HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout.

2. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
a. Temporarily tighten the front disc brake bleeder plug to the disc brake cylinder assembly.
3. INSTALL PISTON SEAL
a. Apply lithium soap base glycol grease to the new piston seals.





b. Install the piston seals to the disc brake cylinder assembly.
4. INSTALL FRONT DISC BRAKE PISTON
a. Apply lithium soap base glycol grease to the front disc brake pistons and a new cylinder boots.
b. Install the cylinder boot to the front disc brake piston.





c. Install the piston to the front disc brake cylinder assembly.

NOTICE: Do not install the piston forcibly in the disc brake cylinder.





5. INSTALL CYLINDER BOOT
a. Install the cylinder boots to the front disc brake cylinder.

NOTICE:
^ Install the boots securely to the grooves of the cylinder and piston.
^ Do not damage the cylinder boot.

INSTALLATION





1. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
a. Install the caliper with the 2 bolts.
Torque: 78.4 Nm (800 kgf-cm, 58 ft. lbs.)





2. CONNECT FRONT FLEXIBLE HOSE
a. Connect the flexible hose with the union bolt and a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder assembly.





3. INSTALL DISC BRAKE PAD AND ANTI-SQUEAL SHIMS

HINT: Install the clip lock securely in the groove of the pad.

a. Apply disc brake grease to the anti-squeal shims and install them to each pad.

NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pad. Install each shim in the correct position and direction. There should be no oil or grease on the friction surfaces of the pads and the disc.





4. INSTALL FRONT DISC BRAKE ANTI-RATTLE SPRING
a. Install the hole pin while pushing on the front disc brake anti-rattle spring.
b. Install the clip.
5. INSTALL FRONT DISC BRAKE WITH HOLE PIN
6. FILL RESERVOIR WITH BRAKE FLUID
7. BLEED BRAKE LINE
8. BLEED BRAKE ACTUATOR ASSEMBLY
9. INSPECT FLUID LEVEL IN RESERVOIR
10. INSPECT FOR BRAKE FLUID LEAKAGE
11. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)