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BODY REPAIR BL-277
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D E
F
G H
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K L
M A
B
BL
Revision: 2006 July 2007 FX35/FX45
Change parts
Rear end crossmember assembly
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BL-278
BODY REPAIR
Revision: 2006 July 2007 FX35/FX45
REAR FLOOR REAR
Work after rear panel assembly and rear end crossmember assembly have been removed.
SIIA2718E
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BODY REPAIR BL-279
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B
BL
Revision: 2006 July 2007 FX35/FX45
SIIA2719E
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BL-280
BODY REPAIR
Revision: 2006 July 2007 FX35/FX45
SIIA2286E
Change parts
Rear floor rear Spare tire clamp bracket
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BODY REPAIR BL-281
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BL
Revision: 2006 July 2007 FX35/FX45
REAR SIDE MEMBER EXTENSION
Work after rear panel assembly and rear end crossmember assembly have been removed.
SIIA2287E
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BL-282
BODY REPAIR
Revision: 2006 July 2007 FX35/FX45
Change parts
Rear side member extension (LH)
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BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION
A
B
BR
Revision: 2006 July 2007 FX35/FX45
BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ............................................................. ..... 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions for Brake System ............................. ..... 3
PREPARATION ...................................................... ..... 4
Commercial Service Tools ................................... ..... 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 5
NVH Troubleshooting Chart ................................ ..... 5
BRAKE PEDAL ..................................................... ..... 6
Inspection and Adjustment .................................. ..... 6
ADJUSTMENT ................................................. ..... 6
Components ........................................................ ..... 7
Removal and Installation ..................................... ..... 7
REMOVAL ........................................................ ..... 7
INSPECTION AFTER REMOVAL .................... ..... 8
INSTALLATION ................................................ ..... 8
BRAKE FLUID ....................................................... ..... 9
On-Board Inspection ........................................... ..... 9
LEVEL CHECK ................................................ ..... 9
Drain and Refill .................................................... ..... 9
Bleeding Brake System ....................................... ... 10
BRAKE TUBE AND HOSE .................................... ....11
Hydraulic Circuit .................................................. .... 11
Removal and Installation of Front Brake Tube and
Brake Hose ......................................................... .... 11
REMOVAL ........................................................ .... 11
INSTALLATION ................................................ .... 11
Removal and Installation of Rear Brake Piping and
Brake Hose ......................................................... ... 12
REMOVAL ........................................................ ... 12
INSTALLATION ................................................ ... 12
Inspection After Installation ................................. ... 12
BRAKE MASTER CYLINDER ............................... ... 13
On-Board Inspection ........................................... ... 13
LEAK INSPECTION ......................................... ... 13
Components ........................................................ ... 13
Removal and Installation ..................................... ... 13 REMOVAL ........................................................
... 13
INSTALLATION ................................................ ... 14
Disassembly and Assembly ................................. ... 14
DISASSEMBLY ................................................ ... 14
ASSEMBLY ...................................................... ... 14
BRAKE BOOSTER ................................................ ... 15
On-Vehicle Service .............................................. ... 15
OPERATING CHECK ....................................... ... 15
AIRTIGHT CHECK ........................................... ... 15
Components ........................................................ ... 15
Removal and Installation ..................................... ... 16
REMOVAL ........................................................ ... 16
INSPECTION AFTER REMOVAL .................... ... 16
INSTALLATION ................................................ ... 16
VACUUM LINES .................................................... ... 17
Components ........................................................ ... 17
Removal and Installation ..................................... ... 17
Inspection ............................................................ ... 18
VISUAL INSPECTION ...................................... ... 18
CHECK VALVE INSPECTION .......................... ... 18
FRONT DISC BRAKE ............................................ ... 19
On-Vehicle Inspection .......................................... ... 19
PAD WEAR INSPECTION ................................ ... 19
Components ........................................................ ... 19
Removal and Installation of Brake Pad ............... ... 20
REMOVAL ........................................................ ... 20
INSTALLATION ................................................ ... 20
Removal and Installation of Brake Caliper Assembly ... 20
REMOVAL ........................................................ ... 20
INSTALLATION ................................................ ... 21
Disassembly and Assembly of Brake Caliper
Assembly ............................................................. ... 21
DISASSEMBLY ................................................ ... 21
INSPECTION AFTER DISASSEMBLY ............. ... 22
ASSEMBLY ...................................................... ... 22
DISC ROTOR INSPECTION ............................ ... 24
Brake Burnishing Procedure ................................ ... 24
REAR DISC BRAKE .............................................. ... 25
On-Vehicle Inspection .......................................... ... 25
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BR-2Revision: 2006 July 2007 FX35/FX45
PAD WEAR INSPECTION ................................
... 25
Components ........................................................ ... 25
Removal and Installation of Brake Pad ................ ... 26
REMOVAL ........................................................ ... 26
INSTALLATION ................................................. ... 26
Removal and Installation of Brake Caliper Assembly ... 26
REMOVAL ........................................................ ... 26
INSTALLATION ................................................. ... 26
Disassembly and Assembly of Brake Caliper
Assembly ............................................................. ... 27
DISASSEMBLY ................................................ ... 27 INSPECTION AFTER DISASSEMBLY .............
... 28
ASSEMBLY ....................................................... ... 28
DISC ROTOR INSPECTION ............................ ... 30
Brake Burnishing Procedure ................................ ... 30
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 31
General Specifications ......................................... ... 31
Brake Pedal ......................................................... ... 31
Brake Booster ...................................................... ... 31
Check Valve ......................................................... ... 31
Front Disc Brake .................................................. ... 31
Rear Disc Brake ................................................... ... 31