
REAR DISC BRAKE
BR-41
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DISASSEMBLY
BRAKE CALIPER ASSEMBLY : Removal and InstallationINFOID:0000000003811215
REMOVAL
WARNING:
1. Brake caliper assembly
Refer to GI-4, "
Components" for symbols in the figure.
JPFIA0311GB
1. Sliding pin bolt 2. Bushing 3. Cap
4. Bleeder valve 5. Cylinder body 6. Piston seal
7. Piston 8. Piston boot 9. Sliding pin boot
10. Torque member
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0355GB

BR-42
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1. Remove tires.
2. Fix the disc rotor using wheel nuts.
3. Drain brake fluid. Refer to BR-9, "
Draining".
CAUTION:
Never spill or splash brake fluid on the disc rotor.
4. Remove union bolt and copper washers then disconnect brake hose from caliper assembly.
5. Remove torque member mounting bolts, and remove brake caliper assembly.
CAUTION:
Never drop brake pads and caliper assembly.
6. Remove disc rotor.
CAUTION:
Put matching marks on the wheel hub and bearing assembly and the disc rotor before removing
the disc rotor.
Never drop disc rotor.
INSTALLATION
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
1. Install disc rotor.
CAUTION:
Align the matching marks put during removal when reusing the disc rotor.
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face,
threads, mounting bolts, and washers. Wipe out any grease and moisture.
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified
torque. Refer to BR-22, "
REAR : Exploded View".
CAUTION:
Never reuse copper washer.
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
Never spill or splash brake fluid on the disc rotor.
5. Check that no drag feel is present for the rear disc brake. Refer to BR-44, "
BRAKE CALIPER ASSEMBLY
: Inspection".
BRAKE CALIPER ASSEMBLY : Disassembly and AssemblyINFOID:0000000003811216
DISASSEMBLY
NOTE:
Never remove the torque member and pad retainers when disassembling and assembling the cylinder body.
1. Remove the sliding pin bolts and remove the cylinder body from the torque member.
2. Remove brake pads and shims. Refer to BR-39, "
BRAKE PAD : Exploded View".
3. Remove sliding pin boots from torque member.
4. Remove bushing from sliding pin bolt.

REAR DISC BRAKE
BR-43
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5. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston.
6. Remove piston seal from cylinder body using suitable tool.
CAUTION:
Be careful not to damage a cylinder inner wall.
7. Remove bleeder valve and cap.
ASSEMBLY
1. Install bleeder valve and cap.
2. Apply rubber grease to piston seal (1), and install to cylinder
body.
CAUTION:
Never reuse piston seal.
3. Apply rubber grease to piston boot (1). Cover the piston (2) end
with the piston boot, and then install cylinder side lip on the pis-
ton boot securely into the groove on cylinder body.
CAUTION:
Never reuse piston boot.
BRD0041D
JPFIA0038ZZ
JPFIA0039ZZ
JPFIA0040ZZ

BR-44
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
4. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, install bushing to sliding pin
bolt.
6. Apply rubber grease to the sliding pin bolts and the sliding pin
boots, install sliding pin boot to torque member.
7. Install the cylinder body to the torque member and tighten the
sliding pin bolts to the specified torque.
BRAKE CALIPER ASSEMBLY : InspectionINFOID:0000000003811217
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal
condition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is
detected.
Piston
Check the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin Bolt, Sliding Pin Boot and Bushing
Check the sliding pin bolts and sliding pin boots for rust, wear, cracks or damage. Replace the parts if any
abnormal condition is detected.
INSPECTION AFTER INSTALLATION
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads.
3. Press the piston.
CAUTION:
Never damage the piston boot.
When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake
fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
4. Install brake pads.
5. Depress the brake pedal several times.
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
42, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surfaces after refinishing or replacing disc rotors, or if a soft pedal occurs at very low mile-
age. Refer to BR-15, "
DISC ROTOR : Inspection and Adjustment".
JPFIA0041ZZ

FAX-1
TRANSMISSION & DRIVELINE
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SECTION FA X
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CONTENTS
FRONT AXLE
SYMPTOM DIAGNOSIS ..... ..........................2
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................ .....
2
NVH Troubleshooting Chart ................................ ......2
PRECAUTION ...............................................3
PRECAUTIONS .............................................. .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect .....................................
3
Precautions for Drive Shaft .......................................3
PREPARATION ............................................5
PREPARATION .............................................. .....5
Special Service Tool ........................................... ......5
ON-VEHICLE MAINTENANCE .....................6
FRONT WHEEL HUB AND KNUCKLE ......... .....6
Inspection ............................................................ ......6
FRONT DRIVE SHAFT ........................................7
Inspection ............................................................ ......7
ON-VEHICLE REPAIR ..................................8
FRONT WHEEL HUB AND KNUCKLE ......... .....8
Exploded View .................................................... ......8
Removal and Installation ...........................................8
Inspection ..................................................................9
FRONT DRIVE SHAFT BOOT ..........................10
Exploded View ..................................................... ....10
WHEEL SIDE ......................................................... ....12
WHEEL SIDE : Removal and Installation ................12
TRANSAXLE SIDE ................................................ ....15
TRANSAXLE SIDE : Removal and Installation .......15
Inspection ............................................................ ....15
FRONT DRIVE SHAFT .....................................16
Exploded View .........................................................16
LEFT SIDE ............................................................. ....18
LEFT SIDE : Removal and Installation ....................18
RIGHT SIDE ........................................................... ....19
RIGHT SIDE : Removal and Installation ..................19
WHEEL SIDE ......................................................... ....20
WHEEL SIDE : Disassembly and Assembly ...........20
TRANSAXLE SIDE ................................................ ....22
TRANSAXLE SIDE : Disassembly and Assembly ....22
Inspection ............................................................ ....33
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .............................................
35
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
35
Wheel Bearing ..................................................... ....35
Drive Shaft ...............................................................35

PREPARATION
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PREPARATION
PREPARATION
Special Service ToolINFOID:0000000003811072
Tool number
Tool nameDescription
KV40107300
Boot band crimping toolInstalling boot band
KV40107500
Drive shaft attachmentRemoving drive shaft
KV38107900
Protector
a: 32 mm (1.26 in) dia.Installing drive shaft
ZZA1229D
ZZA1230D
PDIA1183J

FRONT DRIVE SHAFT
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FRONT DRIVE SHAFT
InspectionINFOID:0000000003811075
Check drive shaft mounting point and joint for looseness and other damage.
Check boot for cracks and other damage.
CAUTION:
Replace drive shaft assembly when noise or vibration occur from drive shaft.

FRONT WHEEL HUB AND KNUCKLE
FAX-9
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11. Temporarily tighten strut assembly and steering knuckle.
12. Remove wheel hub and bearing assembly, and then remove splash guard.
13. Remove steering outer socket from steering knuckle. Refer to ST-18, "
Exploded View".
14. Remove steering knuckle from transverse link and strut assembly.
INSTALLATION
Note the following, and install in the reverse order of the removal.
Install removed wheel hub and bearing assembly and steering knuckle and perform the final tightening of
each part under unladen conditions on the level surface.
Never reuse cotter pin.
InspectionINFOID:0000000003811078
INSPECTION AFTER REMOVAL
Check components for deformation, cracks, and other damage. Replace if necessary.
Ball Joint Inspection
Check boots of transverse link and steering outer socket ball joint for breakage, axial play, and torque. Refer to
FSU-12, "
Inspection" and ST-26, "Inspection".
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-57, "FRONT WHEEL SENSOR :
Exploded View" (without VDC), BRC-151, "FRONT WHEEL SENSOR : Exploded View". (with VDC).
2. Check the wheel alignment. Refer to FSU-7, "
Wheel Alignment Inspection".
3. Adjust neutral position of steering angle sensor (with VDC). Refer to BRC-66, "
ADJUSTMENT OF
STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".