Rear Disc Brake

REAR DISC BRAKE


Disassembly and Assembly of Caliper Assembly


WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:
- While removing caliper, do not depress brake pedal because piston will pop out.
- It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang caliper with a wire so as not to stretch brake hose.
- Do not damage piston boot.
- If any shim is subject to serious corrosion, replace it with a new one.
- Always replace shim and shim cover as a set when replacing brake pads.
- Keep rotor free from brake fluid.
- Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Rear Disc Brake.

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

DISASSEMBLY
1. Remove the cylinder body from the torque member. Removal And Installation Of Caliper Assembly.
2. Remove sliding pin boot from the torque member.





3. Remove the retaining ring from the cylinder body using a suitable tool as shown. Discard the retaining ring.

CAUTION:
Do not reuse the retaining ring.





4. Place a wooden block as shown, and blow air from union bolt hole to remove piston and piston boot.

WARNING:
Do not place your finger in front of piston.





5. Remove piston seal from cylinder body using a suitable tool as shown.

CAUTION:
Be careful not to damage cylinder inner wall.

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 and Sliding Pin Boot
Check sliding pins and sliding pin boots for wear, damage, and cracks. Replace affected parts as necessary.

ASSEMBLY





1. Apply a rubber grease to the new piston seal and install into the cylinder body.

CAUTION:
Do not reuse the piston seals.





2. Apply rubber grease to the new piston boot and install on the piston, then firmly insert the new piston boot cylinder-side lip into the cylinder body groove.

CAUTION:
Do not reuse the piston boot.





3. Apply a brake fluid to the piston then insert it into the cylinder body by hand and firmly attach the new piston boot piston-side lip into the new piston boot.

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





4. Install the new retaining ring to hold the piston boot.

CAUTION:
- Make sure the boot is firmly in the cylinder body groove.
- Do not reuse the retaining ring.
5. Attach the sliding pin boot to the torque member.
6. Install the cylinder body on the torque member. Removal And Installation Of Caliper Assembly.

DISC ROTOR INSPECTION

Visual Inspection
Check surface of the disc rotor for uneven wear, cracks or serious damage. Replace as necessary.

Runout Inspection
1. Secure disc rotor to the wheel hub in two or more positions, using wheel nuts.





2. Inspect runout using a dial gauge located at a point 10 mm (0.39 in) from the edge.

CAUTION:
Before measuring, make sure the axle end play is with specification. Procedures.

Runout limit : Refer to Rear Disc Brake.

3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of the disc rotor and wheel hub by one hole.
4. If runout is still out of specification, turn the disc rotor using Tool until runout is with the specified limit.

Tool number : 38-PFM90.5 ( - )


Thickness Inspection





Using a micrometer, check thickness of the disc rotor. If thickness is not within specification, replace disc rotor.

Repair limit thickness : Refer to Rear Disc Brake.