Page 937 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 59
CALIPER REPLACEMENT
7
1
4
6
8
8
5
2
3
Removal Steps
1. Wheel and tire assembly
2. Brake flexible hose
3. Lock bolt
4. Guide bolt
5. Caliper assembly
6. Support bracket
7. Pad assembly with shim
8. Clip
Installation Steps
To install, follow the removal steps in the
reverse order.
REMOVAL
•Raise the vehicle and support with suitable safety
stands.
1. Wheel and Tire Assembly
•Refer to Wheels and Tires in Suspension section.
2. Brake Flexible Hose
1) Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper.
2) After disconnecting the flexible hose, cap or tape
the openings to prevent entry of foreign material.
3) Since the brake fluid flows out from the
connecting coupler, place a drain pan under the
vehicle.
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5C – 60 POWER ASSISTED BRAKE SYSTEM
3. Lock Bolt
4. Guide Bolt
4
3
5. Caliper Assembly
6 Support Bracket
•Take care not to damage the flexible brake hose
when removing the support bracket.
7. Pad Assembly with Shim
•Mark the lining locations if they are to be
reinstalled.
8. Clip
INSTALLATION
8. Clip
Clip
7. Pad Assembly with Shim
•Apply special grease (approx. 0.2 g) to both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.Inner shim
Wear indicator
6. Support Bracket
Support Bracket Torque N·m (kg·m / lb·ft)
104 (10.6 / 77)
5. Caliper Assembly
Page 939 of 3573
POWER ASSISTED BRAKE SYSTEM 5C – 61
4. Guide Bolt
3. Lock Bolt
Lock Bolt Torque N·m (kg·m / lb·ft)
44 (4.5 / 32)
3
4
2. Brake Flexible Hose
1) Always use new gaskets.
2) Be sure to put the hooked edge of the flexible
hose end into the anti-rotation cavity.
Brake Flexible Hose Torque N·m (kg·m / lb·ft)
35 (3.5 / 26)
Hooked edge
Gasket
1. Wheel and Tire Assembly
1) Refer to Wheels and Tires in Suspension section.
2) Bleed brakes.
Page 940 of 3573
5C – 62 POWER ASSISTED BRAKE SYSTEM
REBUILDING THE CALIPER
3465
7
9
1
23
8
Disassembly Steps
1. Guide bolt
2. Lock bolt
3. Dust boot
4. Dust boot ring
5. Piston
6. Dust boot; piston
7. Piston seal
8. Bleeder with cap
9. Caliper body
Reassembly Steps
9. Caliper body
8. Bleeder with cap
7. Piston seal
5. Piston
6. Dust boot; pisotn
4. Dust boot ring
3. Dust boot
2. Lock bolt
1. Guide bolt
DISASSEMBLY
1. Guide Bolt
2. Lock Bolt
3. Dust Boot
4. Dust Boot Ring
•Using a small screwdriver, remove the dust boot
ring.
Page 941 of 3573

POWER ASSISTED BRAKE SYSTEM 5C – 63
5. Piston
•Insert a block of wood into the caliper and force
out the piston by blowing compressed air into the
caliper at the flexible hose attachment. This
procedure must be done prior to removal of dust
boot.
WARNING:
DO NOT PLACE YOUR FINGERS IN FRONT OF THE
PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT
WHEN APPLYING COMPRESSED AIR. THIS COULD
RESULT IN PERSONAL INJURY.
CAUTION:
Use just enough air to ease the piston out of the
bore. If the piston is blown out, it may be damaged.
6. Dust Boot; Piston
7. Piston Seal
8. Bleeder with Cap
9. Caliper Body
REASSEMBLY
9. Caliper Body
8. Bleeder with Cap
Bleeder Torque N·m (kg·cm / lb·in)
8 (80 / 69)
7. Piston Seal
•Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in
the repair kit.
INSPECTION AND REPAIR
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts;
•Rotor
•Cylinder body
•Cylinder bore
•Piston
•Slide pin
•Support bracket
NOTE:
The piston dust seal and dust boot are to be replaced
each time the caliper is overhauled.
Discard these used rubber parts and replace with
new ones.
5. Piston
Page 942 of 3573
5C – 64 POWER ASSISTED BRAKE SYSTEM
6. Dust Boot; Piston
•When inserting the piston into the cylinder, use
finger pressure only. Do not use a mallet or other
impact tools, since damage to the cylinder wall or
piston seal can result.
4. Dust Boot Ring
•Apply special grease (Approx. 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
3. Dust Boot
•Install the dust boot on the support bracket after
applying special grease (Approx 1 g) onto the
dust boot inner surface. Also apply special grease
onto the lock bolt and guide bolt setting hole of
the support bracket.
2. Lock Bolt
1. Guide Bolt
Guide Bolt Torque N·m (kg·m / lb·ft)
44 (4.5 / 32)
Page 943 of 3573

POWER ASSISTED BRAKE SYSTEM 5C – 65
UNIT REPAIR
MASTER CYLINDER
The master cylinder is not repairable and must be
replaced as complete assembly if found defective.
INSPECTION
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective.
In such cases perform the following visual check.
Visual check
Make parts replacement as required if wear,
distortion, nicks, cuts, corrosion, or other abnormal
conditions are found through the following parts
inspection;
•Master cylinder body
•Fluid reservoir
•O-ring
Primary piston
FUNCTIONAL INSPECTION OF MASTER
CYLINDER PISTON
Push the primary piston with your fingers to check
that it travels smoothly. If the motion is questionable,
replace the master cylinder as a complete assembly.
FUNCTIONAL INSPECTION OF MASTER
CYLINDER
Inspect the master cylinder for function as follows. If
any abnormal function is found, replace with a new
one.
Primary piston holder: 5-8840-2306-0 (J-39242)
(including master cylinder attachment and master
cylinder plug)
•Install the primary piston holder onto the master
cylinder with the spacer (2 bolts) with its adjusting
bolt screwed in up to the “0” line.
Master cylinder
Spacer
5-8840-2306-0
Primary piston holder"0" line
"5" line
Page 944 of 3573

5C – 66 POWER ASSISTED BRAKE SYSTEM
Radiator cap tester: 5-8840-0277-0 (J-24460-01)
•Connect master cylinder attachment with the end
of radiator cap tester, and apply air pressure with
the cap tester. Make sure there is no rise in
pressure and that with the adjusting bolt further
screwed in 5 mm (align the adjusting bolt to the
“5” line). There should be a pressure increase of
49 kpa (0.5 kg/cm
2/7.1 psi) or more.
NOTE:
When checking the front (or primary) side, be sure to
mount master cylinder plug in the rear (or secondary)
port.
NOTE:
1) Do not use an air compressor, as the air from
compressor is mixed with compressor oil.
2) When installing the master cylinder onto the
vacuum booster, always adjust vacuum booster
push rod. (Refer to Vacuum Booster Assembly in
this section.)
3) After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and pedal
free play.
Master cylinder
plug
Master cylinder attachment
5-8840-0277-0
Radiator cap tester
5-8840-2306-0
“0” line“5” line
Apply air No pressure Pressure
pressure to rise. increase of
the front and
49 kpa (0.5 kg/cm2/
rear ports 7.1 psi) more
Remarks Check port into Checks air
the atmospheric tightness of the
pressure pressure
chamber chamber