Page 2617 of 3000
BRAKE – FRONT BRAKEBR–31
BR
7. REMOVE FRONT DISC BRAKE CYLINDER
ASSEMBLY LH
(a) Install the front disc brake cylinder sub-assembly
with the 2 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
(b) Install a 2 new gaskets and flexible hose with the
union bolt.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
HINT:
Install the flexible hose lock securely in the lock hole
in the disc brake cylinder.
8. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
3)
9. BLEED BRAKE MASTER CYLINDER (See page BR-3)
10. BLEED BRAKE LINE (See page BR-4)
11. BLEED BRAKE ACTUATOR (w/ VSC) (See page BR-
4)
12. CHECK FLUID LEVEL IN RESERVOIR (See page BR-
7)
13. CHECK BRAKE FLUID LEAKAGE
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
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Page 2618 of 3000
BRAKE – FRONT BRAKEBR–23
BR
BRAKE
BRAKE
FRONT BRAKE
COMPONENTS
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Page 2619 of 3000

BR–24BRAKE – FRONT BRAKE
BR
REMOVAL
HINT:
Remove the RH side by the same procedure as the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it attaches to
any painted surface.
3. REMOVE FRONT DISC BRAKE CYLINDER SUB-
ASSEMBLY
(a) Remove the union bolt and 2 gaskets from the front
disc brake cylinder sub-assembly, then disconnect
the flexible hose.
(b) Hold the front disc brake cylinder slide pin and
remove the 2 bolts.
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the disc brake pad kit front from the front
disc brake cylinder mounting LH.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the anti squeal shim and pad wear
indicator plate from the each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT
PLATE
(a) Remove the front disc brake pad support plate (No.
1) and front disc brake pad support plate (No. 2)
from the front disc brake cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the front disc brake cylinder slide pin (No.
1) and front disc brake cylinder slide pin (No. 2) from
the front disc brake cylinder mounting LH.
8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE
BUSH
(a) Using a screwdriver, remove the front disc brake
cylinder slide bush from the front disc brake cylinder
slide pin (No. 2).
NOTICE:
Do not damage the front disc brake cylinder
slide pin (No. 2).
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Page 2620 of 3000
BRAKE – FRONT BRAKEBR–25
BR
9. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and front disc brake cylinder
mounting LH.
F045344
Page 2621 of 3000

BR–26BRAKE – FRONT BRAKE
BR
DISASSEMBLY
1. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake
cylinder mounting LH in the vise through aluminum
plates.
(b) Using a screwdriver and hammer, remove the 2
front disc brake bush dust boots from the front disc
brake cylinder mounting LH.
2. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and
cylinder boot.
3. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug, between the front disc brake
piston and the disc brake cylinder sub-assembly.
(b) Use compressed air to remove the front disc brake
piston from the disc brake cylinder sub-assembly.
CAUTION:
Do not place your fingers in front of the piston
when using compressed air.
NOTICE:
Do not spatter the brake fluid.
4. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from
the front disc brake cylinder sub-assembly.
NOTICE:
Do not damage the inner cylinder and cylinder
groove.
5. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the
front disc brake cylinder sub-assembly.
6. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
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Page 2622 of 3000
BRAKE – FRONT BRAKEBR–27
BR
7. REMOVE FRONT DISC
(a) Place matchmarks on the front disc and the axle
hub.
(b) Remove the front disc.
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Page 2623 of 3000

BR–28BRAKE – FRONT BRAKE
BR
INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the brake cylinder bore and front disc brake
piston for rust or scoring.
2. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Standard thickness:
12.0 mm (0.472 in.)
Minimum thickness:
1.0 mm (0.039 in.)
3. INSPECT FRONT DISC BRAKE PAD SUPPORT
PLATE
(a) Inspect the front disc brake pad support plate (No.
1) and front disc brake pad support plate (No. 2).
Make sure that they have sufficient rebound, no
deformation, cracks or wear, and have had all rust
and dirt cleaned off.
4. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness:
28.0 mm (1.102 in.)
Minimum thickness:
26.0 mm (1.024 in.)
REASSEMBLY
1. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
Select the installation position where the disc has
the minimum runout.
2. INSPECT DISC RUNOUT
(a) Temporarily fasten the disc with the hub nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Using a dial indicator, measure the disc runout 10
mm (0.39 in.) away from the outer edge of the disc.
Maximum disc runout:
0.05 mm (0.0020 in.)
(c) If the disc runout is the maximum value or greater,
check the bearing play in the axial direction and
check for the axle hub runout (See page AH-5). If
the bearing play and axle hub runout are normal,
adjust the disc runout or grind it on a "On-car" brake
lathe.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE
BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug
to the front disc brake cylinder sub-assembly.
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Page 2624 of 3000

BRAKE – FRONT BRAKEBR–29
BR
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
5. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new
piston seal.
(b) Install the piston seal to the front disc brake cylinder
sub-assembly.
6. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front
disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the front disc brake
piston.
(c) Install the front disc brake piston to the front disc
brake cylinder sub-assembly.
NOTICE:
Do not install the piston forcibly in the front disc
brake cylinder sub-assembly.
7. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the front disc brake
cylinder sub-assembly.
NOTICE:
Install the boot securely to the grooves of the
cylinder and piston.
(b) Using a screwdriver, install the set ring.
NOTICE:
Do not damage the cylinder boot.
8. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake
cylinder mounting LH in the vise through aluminum
plates.
(b) Place front disc brake cylinder mounting LH in vise.
(c) Apply lithium soap base glycol grease to the sealing
surface of 2 new front disc brake bush dust boots.
(d) Using a socket wrench (19 mm) and hammer, drive
the 2 front disc brake bush dust boots to the front
disc brake cylinder mounting LH.
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