Front

FRONT DISC BRAKE

Exploded View BR-23:

CAUTION:
- Clean dust on caliper and brake pad with a vacuum dust collector. Do not blow with compressed air.
- While removing brake pad or cylinder body, do not depress brake pedal because piston will pop out.
- It is not necessary to remove torque member mounting bolts and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so that brake hose is not under tension.
- Do not damage piston boot.
- If any shim is subject to serious corrosion, replace it with a new one.
- Keep rotor free from brake fluid.
- When replacing brake pad, replace shim with a new one.

Disassembly and Assembly of Brake Caliper Assembly

NOTE: Do not remove torque member, brake pads, shims and pad retainers, when disassembling or assembling cylinder body.

DISASSEMBLY





1. Remove caliper assembly from vehicle.
2. Remove sliding pin bolts from cylinder body, and remove pads, shims and pad retainers from torque member, if necessary.

CAUTION: When removing pad retainer from torque member, lift the pad retainer in the direction shown by arrow, so as not to deform it.





3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown, and blow air from union bolt mounting hole to remove piston and piston boot.

CAUTION: Do not get fingers caught in the piston.





5. Remove piston seal with a flat-bladed screwdriver.

CAUTION: Be careful not to damage the inner wall of cylinder.

INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner wall of cylinder for corrosion, wear, and damage. Replace cylinder body as necessary.

CAUTION: Clean cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.

Torque Member
Check for wear, cracks, and damage. Replace torque member as necessary.

Piston
Check piston surface for corrosion, wear, and damage. Replace piston as necessary.

CAUTION: The piston sliding surface is plated. Do not polish with sandpaper.

Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins, sliding pin bolts and sliding pin boots for wear, damage, and cracks. Replace applicable part as necessary.

ASSEMBLY

CAUTION: When assembling, use only specified rubber lubricant.





1. Apply polyglycol ether based lubricant to new piston seal and install them to cylinder body.





2. Apply rubber grease to piston boot and apply brake fluid to piston. Cover the piston end with piston boot, and install cylinder-side lip on piston boot properly into groove on cylinder body.





3. Press piston into cylinder body by hand to assemble piston-side lip on piston boot properly into a groove on piston.

CAUTION: Press piston evenly and change pressing point to prevent inner wall of cylinder from being rubbed.

4. Install sliding pins and sliding pin boots to the torque member.
5. If pads, shims and pad retainers were removed, install them to torque member.
6. Install cylinder body to torque member.
7. Install sliding pin bolts.
8. Install caliper assembly to vehicle.
9. Tighten sliding pin bolts to specified torque. Refer to Exploded View BR-23.