Removal And Installation Of Caliper Assembly

REAR DISC BRAKE


Removal and Installation 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. Adjustment.

REMOVAL
1. Drain a quarter of the brake fluid from the reservoir.
2. Remove rear wheels and tires using power tool.
3. Secure disc rotor using wheel nuts.
4. Remove the union bolt to disconnect the rear brake hose. Discard the copper washers.

CAUTION:
Do not reuse the copper washers.





5. Remove sliding pins (A) and remove cylinder body from torque member.
6. If necessary, remove torque member and disc rotor. If the disc rotor cannot be removed, remove as follows:
- Make sure parking brake lever is completely disengaged.





- Hold down the disc rotor with the wheel nut and remove the adjuster hole plug.
- Insert a flat-bladed screwdriver through the plug opening and rotate the star wheel on the adjuster assembly in the direction shown to loosen and retract the brake shoes.
- Prior to removing disc rotor, make alignment mark using a marker between the hub and disc rotor.
- Remove wheel nut and rotor.

INSTALLATION
1. If necessary, install disc rotor and torque member.
- Align marks made during removal on the hub and disc rotor.





2. Install cylinder body to the torque member and tighten sliding pins (A) to the specified torque. Component.

CAUTION:
Before installing cylinder body, wipe off oil and grease on mounting surfaces of cylinder body.
3. Install brake hose with new copper washers to cylinder body and tighten union bolt to the specified torque. Component.

CAUTION:
- Do not reuse the copper washers.
- Align brake hose protrusion to groove on cylinder body.
4. Adjust the parking brake. Adjustments.
5. Bleed the brake system. Service and Repair.
6. Install rear wheels and tires. Adjustment.