Rear

Rear Disc Brake Assembly

REMOVAL
1. Lift-up vehicle and remove wheels





2. 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 back plate.

NOTE: Remove support only when replacing it or the rotor It need not be removed when servicing caliper body assembly

6. Clean mud and foreign particles from caliper body assembly and support

CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).

INSTALLATION
1. Install disc rotor on hub
2. Install support on back plate.
Tightening torque: 78 Nm (8.0 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.
^ Replace pads if there is oil or grease on them.

3. Apply thin coat of Molykote AS880N (Part No 26298AC000. to the frictional portion between pad and pad clip

CAUTION: Do not allow oil or grease to adhere to the sliding surface of pad and disc rotor.

4. Install pads on support
5. Install caliper body on support
Tightening torque: 39 Nm (4.0 kgf-cm, 28.9 ft. lbs.)
6. Connect brake hose
Tightening torque: 18 Nm (1.8 kgf-cm, 13.0 ft. lbs.)

CAUTION:
^ The brake hose must be connected without any twist.
^ Replace brake hose gaskets with new ones.

7. Bleed air from brake system

DISASSEMBLY





1. Remove the boot ring.





2. Remove the piston boot.





3. Gradually supply compressed air via inlet of caliper body to force piston out.

CAUTION:
^ Place a wooden block as shown in Figure to prevent damage to piston.
^ Do not apply excessively high-pressure.





4. Remove piston seal from caliper body cylinder.
5. Remove lock pin sleeve and boot from caliper body.
6. Remove guide pin boot.

ASSEMBLY
1. Clean caliper body interior using brake fluid.
2. Apply a coat of brake fluid to 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. Insert piston into cylinder.

CAUTION: Do not force piston into cylinder.

5. Apply a coat of specified grease to boot and fit in groove on ends of cylinder and piston.
Grease: NIGLUBE X-2 (Part No. 003606000)





6. Install the piston boot to the caliper body, and attach boot ring.





7. Apply a coat of specified grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves.
Grease: NIGLUBE RX-2 (Part No. 003606000)
8. Install guide pin boot on caliper body.
9. Install lock pin boot on caliper body and insert lock pin sleeve into place.