Front Disc Brake

FRONT DISC BRAKE

Disassembly and Assembly of Brake 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. Brake Burnishing.
NOTE:
Do not remove torque member, brake pads, shims and pad retainers, when disassembling or assembling cylinder body.

DISASSEMBLY

1.Remove cylinder body from the torque member. Front Disc Brake.





2.Place a wooden block as shown, and blow air from union bolt hole to remove piston and piston boot. Discard the piston boot.

WARNING:
Do not place your fingers in front of piston.





3.Remove piston seal using a suitable tool. Discard the piston seal.

CAUTION:
Be careful not to damage the inner wall of cylinder body.

INSPECTION AFTER DISASSEMBLY

Cylinder Body
Check the inner wall of cylinder for corrosion, wear, and damage. Replace cylinder body as necessary.

CAUTION:
Clean cylinder body using new brake fluid. Never use mineral oils such as gasoline or kerosene.
Torque Member
Check for wear, cracks, and damage. Replace torque member as necessary.
Piston
Check piston surface for corrosion, wear, and damage. Replace piston as necessary.

CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins, sliding pin bolts and sliding pin boots for wear, damage, and cracks. Replace affected parts as necessary.

ASSEMBLY






1.Apply rubber grease to new piston seal and install into cylinder body.





2.Apply rubber grease to new piston boot and apply brake fluid to piston. Cover the piston end with piston boot, and install cylinder-side lip on piston boot properly into groove on cylinder body using a suitable tool.





3.Press piston into cylinder body by hand to assemble piston-side lip on piston boot properly into a groove on piston.

CAUTION:
Press piston evenly and change pressing point to prevent inner wall of cylinder from being rubbed.
4.Install the cylinder body on the torque member. Front Disc Brake.

DISC ROTOR INSPECTION

Visual Inspection
Check surfaces of disc rotor for uneven wear, cracks or serious damage. Replace as necessary.
Runout Inspection
1.Secure disc rotor to wheel hub at two or more positions using wheel nuts.





2.Inspect runout using a dial gauge located at a point 10 mm (0.39
in) from the edge.

CAUTION:
Make sure that wheel bearing axial end play is within the specifications before measuring runout. Testing and Inspection.
Runout limit: Front Disc Brake.
3.If runout is outside the limit, find the minimum runout point by shifting the mounting positions of disc rotor and wheel hub by one hole.
4.If runout is still out of specification, refinish the disc rotor using Tool until runout is with the specified limit.
Tool number: 38-PFM-90.5 (-)
Thickness Inspection





Using a micrometer, check thickness of disc rotor. If thickness is outside the specification, replace disc rotor.
Repair limit thickness: Front Disc Brake.