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BR
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FRONT DISC BRAKE
On Board Inspection INFOID:0000000004305909
PAD WEAR INSPECTION • Check pad thickness from check hole on cylinder body.
Component INFOID:0000000004305910
AD22VK
Standard thickness : Refer to
BR-40, " Front
Disc Brake " .
Repair limit thickness : Refer to BR-40, " Front
Disc Brake " .
AWFIA0526ZZ
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3. Hang cylinder body with a wire, and remove pad return spring,
pads, shims and pad retainers from torque member.
CAUTION:
When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow, so as not to
deform it.
Installation 1. Apply PBC (Poly Butyl Cuprysil) grease or silicone- based grease to the shims. Install shims to pads.
CAUTION:
Securely install shims according to mounting direction of pads.
2. Install pad retainers, pad return spring, shims and pads to the torque member. CAUTION:
• When installing pad retainer, at tach it firmly so that it is
not lifted up from torque member, as shown.
3. Install cylinder body to torque member. CAUTION:
Check the brake fluid level in the reservoir tank for fluid level because brake fluid returns to mas-
ter cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool (commercial se rvice tool) to easily press to piston in.
4. Install lower sliding pin bolt (lower side), and tighten it to the specified torque. Refer to BR-25, " Compo-
nent " .
5. Check brakes for drag.
6. Install front wheel and tire. Refer to WT-7, " Rotation " .
CLZ25VF
Removal 1. Remove the front wheel and tire using power tool.
2. Remove sliding pin bolt (lower side).
3. Hang cylinder body with a wire, and remove pads, shims and pad retainers from torque member.
CAUTION:
When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow, so as not to
deform it.
Installation SBR556E
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Compo-
nent " .
5. Check brake for drag.
6. Install the front wheel and tire. Refer to WT-7, " Rotation " .
Removal and Installation of Brake Caliper Assembly INFOID:0000000004305912
REMOVAL
1. Remove front wheel and tire.
2. Secure the disc rotor using wheel nuts. CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it is necessary to remove the disc rotor.
3. Drain brake fluid. Refer to BR-9, " Drain and Refill " .
4. Remove the union bolt (A) and discard the copper washers. Remove the brake hose from the cylinder body.
• Protusions (B)
CAUTION:
Do not reuse the copper washers AWFIA0502ZZ
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5. Remove the torque member bolts and remove the cylinder body
and torque member as an assembly.
INSTALLATION 1. Install the torque member and cylinder body as an assembly and tighten the torque member bolts to the specified torque.
Refer to BR-25, " Component " .
CAUTION:
Before installing torque member to vehicle, wipe oil and
grease on mounting surface of steering knuckle and torque
member.
2. Install the brake hose to caliper assembly with new copper washers. Align the brake hose tab between the protusions (B)
on the cylinder body as shown. Tighten the union bolt (A) to the
specified torque. Refer to BR-11, " Hydraulic Circuit " .
CAUTION:
Do not reuse the copper washers
3. Refill with new brake fluid and bleed air. Refer to BR-9, " Bleeding Brake System " .
4. Check front disc brake for drag.
5. Install front wheel and tire. Refer to WT-7, " Rotation " .
Disassembly and Assembly of Brake Caliper Assembly INFOID:0000000004305913
DISASSEMBLY 1. Remove the caliper assembly. Refer to BR-28, " Removal and Installation of Brake Caliper Assembly " .AWFIA0502ZZ
SFIA1137E
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BR-30< SERVICE INFORMATION >
FRONT DISC BRAKE
2. Remove sliding pin bolts and remove cylinder body from the torque member. Remove pads, shims, pad return spring
(AD22VK) and pad retainers from torque member as necessary.
CAUTION:
When removing pad retainer fr om 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.
CAUTION:
Do not get fingers caught in the piston.
5. Remove piston seal with a flat-bladed screwdriver. CAUTION:
Be careful not to damage the inner wall of cylinder.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of cylinder for corrosion, w ear, 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. R eplace 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, cr acks, and serious damage. Replace as necessary.
Runout Inspection
1. Using wheel nuts, secure disc rotor to wheels hub at two or more positions. SBR556E
WFIA0525E
SFIA2277E
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2. Using a dial indicator, check runout.
CAUTION:
Make sure that wheel bearing axi al end play is within the
specifications before measuring runout. Refer to FAX-6," On-Vehicle Inspection and Service " .
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 specific ation, grind rotor on-car using Tool until runout is within the specified limit.
Thickness Inspection Using a micrometer, check thickness of disc rotor. If thickness is out-
side the specifications, replace disc rotor.
ASSEMBLY CAUTION:
When assembling, use only specified lubricant.
1. Apply rubber grease to new piston seal and install on cylinder body.
2. Apply rubber grease (CL25VF) or polyglycol ether based lubri- cant (AD22VK) 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. Runout limit
[measured at 10.0 mm (0.394
in) inside the disc edge] : Refer to
BR-40, " Front
Disc Brake " .
Tool number : 38-PFM90.5 ( — ) Front
Disc Brake " .
Repair limit thickness : Refer to BR-40, " Front
Disc Brake " .
Maximum uneven wear
(measured at 8 positions) : Refer to
BR-40, " Front
Disc Brake " .
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" Removal and Installation of Brake Pad " .
6. Install cylinder body to torque member.
7. Tighten sliding pin bolts to specified torque. Refer to BR-25, " Component " .
8. Install the caliper assembly. Refer to BR-28, " Removal and Installation of Brake Caliper Assembly " .
Brake Burnishing Procedure INFOID:0000000004305914
Burnish the new braking surfaces according to following procedure after refinishing or replacing disc rotors,
pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because brake does not operate easily until pad and disc rotor are
securely fitted.
• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicl e within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake pedal for a few minutes to cool brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.