Front

Front Disc Brake Assembly

REMOVAL

CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled.

1) Set the vehicle on a lift.
2) Loosen the wheel nuts.
3) Jack-up the vehicle, and then remove the front wheel.





4) Remove the union bolt, and then disconnect the brake hose from caliper body assembly.





5) Remove the bolt securing lock pin to caliper body.
6) Raise the caliper body and move it toward vehicle center to separate it from support.





7) Remove the support from housing.

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

8) Clean mud and foreign particles from the caliper body assembly and support.

INSTALLATION
1) Install the support on housing.
Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.)
2) Apply thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3) Apply thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between inner pad and rubber coated shim.





NOTE:
^ Do not apply grease between outer pad and outer shim.
^ Do not confuse the inner shim with outer shim.

4) Install the pads on support.
5) Install the caliper body on support.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
6) Replace the brake hose gaskets with new ones, and then connect the brake hose.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
7) Bleed air from the 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. K0779GA102)





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. K0779GA102)
8) Install the lock pin boot and guide pin boot on support.