Overhaul

FRONT DISC BRAKE

Disassembly and Assembly of Brake Caliper Assembly


DISASSEMBLY

1.Remove the caliper assembly. Removal and Replacement.





2.Remove sliding pin bolts and remove cylinder body from the torque member. Remove pads, shims, and pad retainers from torque member as necessary.

CAUTION:
When removing pad retainer from torque member, lift the pad retainer in the direction shown by arrow, so as not to deform it.
3.Remove sliding pins and sliding pin boots from torque member.





4.Place a wooden block as shown, and blow air from union bolt mounting hole to remove piston and piston boot.

WARNING:
Do not get fingers caught between the piston and wooden block.





5.Remove piston seal with a suitable tool.

CAUTION:
- Be careful not to damage the inner wall of cylinder.
- Do not reuse the piston seal.

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 applicable part as necessary.

DISC ROTOR INSPECTION

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





2.Using a dial indicator, check runout.

CAUTION:
Make sure that wheel bearing axial end play is within the specifications before measuring runout. Testing and Inspection.

Runout limit [measured at 10.0 mm (0.394 in) inside the disc edge]: Refer to "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 the specification, grind rotor on-car using Tool until runout is within the specified limit.
Tool number: 38-PFM-90.5 (-)
Thickness Inspection





Using a micrometer, check thickness of disc rotor. If thickness is outside the specifications, replace disc rotor.
Standard thickness (new): [1][2]Specifications.
Repair limit thickness: [1][2]Specifications.
Maximum uneven wear (measured at 8 positions): Refer to "Front Disc Brake".

ASSEMBLY


CAUTION:
Use rubber grease during assembly.





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

CAUTION:
Do not reuse the piston seal.





2.Apply rubber grease to 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.





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 sliding pins and sliding pin boots to the torque member.
5.Install pads, shims, shim covers and pad retainers to the torque member. Removal and Replacement.
6.Install cylinder body to torque member.
7.Tighten sliding pin bolts to specified torque. Removal and Replacement.
8.Install the caliper assembly. Removal and Replacement.