Removal And Installation

REAR DISC BRAKE

BRAKE CALIPER ASSEMBLY : Removal and Installation


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 the piston will pop out.
- Do not damage piston boot.
- Keep disc rotor free from brake fluid.
- Refill the brake reservoir with new brake fluid "DOT 3".
- Never reuse drained brake fluid.
NOTE:
When removing hoses or tubes, cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Remove rear wheel and tires. Adjustment.
2.Fasten disc rotor using a wheel nut.
3.Drain brake fluid. Drain and Refill.





4.Remove union bolt (A) and then disconnect brake hose from caliper. Discard the copper sealing washers.

CAUTION:
Do not reuse copper sealing washers.





5.Remove the two torque member bolts (A), and then remove the torque member, caliper and pads as an assembly.

CAUTION:
Do not drop the brake pad and multilayered shim assemblies.
6.Remove the two sliding pin bolts and separate the caliper from the torque member. Remove the brake pad and multilayered shim assemblies from the torque member.





7.Remove the disc rotor.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor, if it necessary to reuse the disc rotor.

INSTALLATION






1.Install the disc rotor.

CAUTION:
Alignment marks of disc rotor and wheel hub put at the time of removal when reusing disc rotor.
2.Apply grease to the multilayered shims and pad retainers. Exploded View.
3.Install the brake pad and multilayered shim assemblies to the torque member. Exploded View.
4.Install the caliper and pad assembly on the torque member, then tighten the two sliding pin bolts to the specified torque. Exploded View.





5.Install the torque member, pads and brake caliper assembly, and tighten the torque member bolts (A) to the specified torque.
Diagrams.

CAUTION:
Before installing wipe off all oil and moisture on all mating surfaces of rear axle and torque member, threads, bolts and washers.





6.Align the L-shaped pin on the brake hose in the hole in the caliper, then install the brake hose with new copper sealing washers (1) and tighten the union bolt (A) to the specified torque. Refer to
Removal And Installation.

CAUTION:
Do not reuse copper sealing washers.
BR
7.Refill with new brake fluid and bleed air. Service and Repair.
8.Check rear disc brake for drag.
9.Install rear wheel and tires. Adjustment.