Front
Front Disc Brake AssemblyREMOVAL
1. Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel.
2. Remove union bolt and disconnect brake hose from caliper body assembly.
CAUTION: Do not spill brake fluid on painted surface. Wash it off immediately.
3. Remove bolt securing lock pin to caliper body.
4. Raise caliper body and move it toward vehicle center to separate it from support.
5. Remove support from housing.
NOTE: Remove support only when replacing it or the rotor. It need not be removed when servicing caliper body assembly.
6. Remove disc rotor from hub.
NOTE: If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
7. Clean mud and foreign particles from caliper body assembly and support.
INSTALLATION
1. Install disc rotor on hub.
2. Install support on housing.
Tightening torque: 78 Nm (8 kgf-cm, 58 ft. lbs.)
CAUTION:
^ Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn.
^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad.
^ When replacing the pads, replace pads of the right and left wheels at the same time.
3. Apply thin coat of Molykote AS880N (Part No. 26298AC000. to the frictional portion between pad and pad clip.
4. Apply thin coat of Molykote AS880N (Part No. 26298AC000. to the frictional portion between pad and inner shim.
5. Install pads on support.
6. Install caliper body on support.
Tightening torque: 39 Nm (4.0 kgf-cm, 28.9 ft. lbs.)
7. Connect brake hose.
Tightening torque: 18 Nm (1.8 kgf-cm, 13.0 ft. lbs.)
CAUTION: Replace brake hose gaskets with new ones.
8. Bleed air from brake system.
DISASSEMBLY
1. Clean mud and foreign particles from the caliper body assembly and support.
CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).
2. Remove the boot from piston end.
3. Place a wooden block as shown in the figure to prevent damage to the piston. Gradually supply compressed air via inlet of the brake hose to force piston out.
4. Remove the piston seal from caliper body cylinder.
CAUTION: Be careful not to scratch the inner surface of cylinder and piston seal groove.
5. Remove the lock pin boot and guide pin boot.
ASSEMBLY
1. Clean the caliper body interior using brake fluid.
2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4. Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston.
Grease: NIGLUBE RX-2 (Part No. K0779GA 102.
5. Insert the piston into cylinder.
CAUTION: Do not force the piston into cylinder.
6. Position the boot in grooves on cylinder and piston.
7. Apply a coat of specified grease to the lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. K0779GA 102)
8. Install the lock pin boot and guide pin boot on support.