FRONT DISC BRAKEBR-29
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FRONT DISC BRAKE
Exploded View of Brake PadsINFOID:0000000005147912
Removal and Installation of Brake PadsINFOID:0000000005147913
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
• While removing cylinder bod y, do not depress brake pedal because piston will pop out.
• It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
• Do not damage piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from brake fluid.
• Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing rotors, after replacing pads, or if a so ft pedal occurs at very low mileage.
REMOVAL
1. Remove front wheel and tires. Refer to WT-49, "Rotation".
2. Partially drain some brake fluid from the reservoir.
3. Remove the sliding pin bolts.
1. Inner multi-layered shim 2. Pad wear sensor 3. Pad retainer
4. Outer shim cover 5. Outer shim6. Outer pad
7. Inner pad 1: Molykote M-77 grease
AWFIA0291GB
Revision: April 20092010 QX56
BR-30
< ON-VEHICLE REPAIR >
FRONT DISC BRAKE
4. Hang cylinder body with a wire, and remove pads, pad retainers,shims, and shim cover from torque member.
CAUTION:
When removing the pad retainer from the torque member,
lift it in the direction indi cated by the arrow as shown so
that it does not deform.
INSTALLATION
1. Push pistons in using suitable tool.
CAUTION:
By pushing in pistons, brake fluid returns to m aster cylinder reservoir tank. Watch the brake fluid
level in the reservoir tank.
NOTE:
Using a suitable tool, makes it easier to push in the pistons.
2. Apply Molykote M-77 grease or equivalent to between shim cover and shim. Install outer shim, outer shim cover to inner pad, and inner multi-layered shim to outer pad.
3. Apply Molykote M-77 grease or equivalent to between pad retainer and pad. Install pad retainers and pads to torque member.
4. Apply Molykote M-77 grease or equivalent to the piston face. Install pad return lever securely to pad wear sensor as shown.
CAUTION:
• Securely assemble pad retainers so that they are not
being lifted up from torque member.
• Both inner and outer pads have a pad return system on
the pad retainer. Install pad return lever securely to pad
wear sensor.
5. Install pads to cylinder body.
6. Install cylinder body to torque member. CAUTION:
In the case of replacing a pad with new one, ch eck the brake fluid level in the reservoir tank
because brake fluid returns to reservoir tank when pressing piston in.
NOTE:
Use a suitable tool to easily press piston.
7. Apply rubber grease and install sliding pin bolts, and tighten to the specified torque. Refer to BR-31,
"Exploded View of Brake Caliper".
8. Check front disc brake for drag.
9. Install front wheel and tires. Refer to WT-49, "
Rotation".
Brake Burnishing ProcedureINFOID:0000000005147914
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are
securely seated.
• 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 vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 through 3 until pad and disc rotor are securely seated.
SBR556E
SBR557E
Revision: April 20092010 QX56
BR-32
< ON-VEHICLE REPAIR >
FRONT DISC BRAKE
5. Remove torque member bolts, and remove brake caliperassembly.
CAUTION:
Do not drop brake pad.
6. Apply matching marks to disc rotor and wheel hub assembly as shown if the disc rotor is to be reused, then remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor
if the disc rotor is to be reused.
INSTALLATION
1. If reusing the disc rotor, use the matching marks to align discrotor on the wheel hub assembly as shown, then install disc
rotor using a wheel nut to hold it in place.
CAUTION:
Use matching marks on wheel hub assembly and disc rotor
if the disc rotor is to be reused.
2. Install brake caliper assembly to vehicle, and tighten torque member bolts to the specified torque.
CAUTION:
Do not allow oil or any moisture on all contact surfaces
between steering knuckle and caliper assembly, bolts, and
washer.
SFIA2437E
SDIA2608E
SDIA2608E
SFIA2437E
Revision: April 20092010 QX56
FRONT DISC BRAKEBR-33
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3. Install brake hose to brake caliper assembly using new copper washers. Align the brake hose to the projection as shown and
tighten union bolts to the specified torque.
CAUTION:
• Do not reuse copper washers.
• Securely attach brake hose to projection on cylinderbody.
4. Refill with new brake fluid and bleed air. Refer to BR-17, "
Bleeding Brake System".
5. Check front disc brake for drag and correct as necessary.
6. Install front wheel and tire. Refer to WT-49, "
Rotation".
SFIA2431E
Revision: April 20092010 QX56
BR-34
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
REAR DISC BRAKE
Exploded View of Brake PadsINFOID:0000000005147917
Removal and Installation of Brake PadINFOID:0000000005147918
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
• While removing cylinder body, do not depress brake pedal because piston will pop out.
• It is not necessary to disconnect brake hose connection except for disassembly or replacement of
caliper assembly. In this case, ha ng cylinder body with a wire so as not to stretch brake hose.
• Do not damage piston boot.
• If any shim is subject to serious corrosion, replace it with a new one.
• Always replace shim and shim cover as a set when replacing brake pads.
• Keep rotor free from brake fluid.
• Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
REMOVAL
1. Remove rear wheel and tires using power tools.
2. Partially drain some brake fluid from the reservoir.
3. Remove the sliding sleeves and sliding pin bolts from the cylinder body.
4. Support the cylinder body with wire, remove pads, shims, cover and retainers.
INSTALLATION
1. Push piston in using suitable tool.
CAUTION:
By pushing in piston, brake fluid returns to mast er cylinder reservoir tank. Watch the brake fluid
level in the reservoir tank.
NOTE:
Using a suitable tool, makes it easier to push in the piston.
1. Inner shim cover 2. Outer pad3. Outer multi-layered shim
4. Pad wear sensor 5. Inner pad (RH)6. Pad retainer
7. Inner pad 8. Inner shim
1: Molykote M-77 grease
AWFIA0293GB
Revision: April 20092010 QX56
REAR DISC BRAKEBR-35
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2. Apply Molykote M-77 grease to knuckle slide where brake pad contacts and to the outer multi-layered
shim, pad retainers and inner shim.
CAUTION:
Do not get grease on the brake pads or brake rotor friction surfaces.
3. Install pads, shims, cover and retainers to cylinder body.
4. Apply rubber grease to the sliding sleeves and install cylinder body, sliding sleeves and sliding pin bolts and tighten to specification. Refer to BR-35, "
Exploded View of Brake Caliper".
5. Check rear disc brake for drag.
6. Install rear wheel and tires. Refer to WT-49, "
Rotation".
Brake Burnishing ProcedureINFOID:0000000005147919
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
• Be careful of vehicle speed because the brake does not operate easily until pad and disc rotor are securely seated.
• 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 vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool the brake.
4. Repeat steps 1 through 3 until pad and disc rotor are securely seated.
Exploded View of Brake CaliperINFOID:0000000005147920
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Knuckle slide 12. Sliding sleeve boot
AWFIA0423GB
Revision: April 20092010 QX56
BR-36
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
Removal and Installation of Brake Caliper and Disc Rotor
INFOID:0000000005147921
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
• While removing cylinder body, do not depress brake pedal because piston will pop out.
• Do not damage piston boot.
• Keep rotor free from brake fluid.
• Refill with new specified brake fluid.
• Burnish brake contact surface after refinishing or re placing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer to BR-35, "
Brake Burnishing Procedure".
REMOVAL
1. Remove rear wheel and tire using power tool.
2. Fasten disc rotor using wheel nut.
3. Remove brake reservoir cap.
4. Remove union bolt and cylinder body bolts, then remove cylin-
der body.
NOTE:
Discard the copper washers, do not reuse.
5. Apply matching marks to disc rotor and wheel hub assembly if the disc rotor is to be reused, then remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor
if the disc rotor is to be reused.
INSTALLATION
1. If reusing the disc rotor, use the matching marks to align disc rotor on the wheel hub assembly, then install
disc rotor using a wheel nut to hold it in place.
CAUTION:
Use matching marks on wheel hub assembly and di sc rotor if the disc rotor is to be reused.
2. Install cylinder body and tighten cylinder body bolts to specification. CAUTION:
Before installing cylinder body to the vehic le, wipe off mating surface of cylinder body.
3. Install brake hose to cylinder body with new copper washers and tighten union bolt to specification.
CAUTION:
• Do not reuse copper washers.
• Securely attach brake hose to projection on cylinderbody.
4. Refill with new brake fluid and bleed. Refer to BR-17, "
Bleeding
Brake System".
5. Check rear disc brake for drag and correct as necessary.
6. Install rear wheel and tire. Refer to WT-49, "
Rotation".
13. Sliding sleeveB. Brake fluid R. Rubber grease
M. Molykote M-77 Front
LFIA0211E
SFIA1137E
Revision: April 20092010 QX56
EM-78
< REMOVAL AND INSTALLATION >
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded ViewINFOID:0000000005149012
Removal and InstallationINFOID:0000000005149013
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Do not start working until exh aust system and engine coolant are cooled sufficiently.
• If items or work required are no t covered by the engine section, follow the applicable procedures.
• Always use the support poin t specified for lifting.
• Use either 2-point lift type or separate type lift. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in
preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-30, "
Garage Jack and
Safety Stand".
REMOVAL
Preparation
1. Rear engine mounting insulator 4WD 2. Rear engine mounting insulator 2WD 3. LH engine mounting bracket
4. LH heat shield plate 5. LH engine mounting insulator 6. RH engine mounting bracket
7. RH heat shield plate 8. RH engine mounting insulator A. Refer to Installation
Front
AWBIA0817GB
Revision: April 20092010 QX56