Front Brake

FRONT BRAKE

Front Brake Components:

REMOVAL
1. REMOVE FRONT WHEEL
Torque: 110 Nm (1,122 kgf-cm, 81 ft. lbs.)

2. DISCONNECT FRONT BRAKE FLEXIBLE HOSE





a) Using SST, disconnect the brake line. Use a container to catch the brake fluid.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)

3. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY





a) Remove the 2 mounting bolts and caliper.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)

4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING
5. REMOVE 2 PADS WITH 4 ANTI-SQUEAL SHIMS

NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off.

DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS





a) Using a screwdriver, remove the 4 cylinder boot set rings and boots.
2. REMOVE FRONT DISC BRAKE PISTON





a) Prepare the wooden plate to hold the pistons.





b) Place the plate between the pistons and insert a pad at one side.
c) Use compressed air to remove the pistons alternately from the cylinder.

CAUTION: Do not place your fingers in front of the pistons when using compressed air.

3. REMOVE PISTON SEAL





a) Using a screwdriver, remove the 4 piston seals from the cylinder.

INSPECTION
1. MEASURE PAD LINING THICKNESS





a) Using a ruler, measure the pad lining thickness.
Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear.

2. MEASURE DISC THICKNESS





a) Temporarily fasten the disc with 3 hub nuts.
b) Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch)
Replace the disc if the thickness of the disc is mat the minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.

3. MEASURE DISC RUNOUT





a) Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge.
Maximum disc runout: 0.07 mm (0.0028 inch)
If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe.

HINT: When the disc runout is outside the specified range, check the front hub bearing in the same way.

4. ADJUST DISC RUNOUT
a) Remove the hub nuts and disc. Reinstall the disc 1/6 of a turn round from its original position on the hub. Install and torque the hub nuts.
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
b) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
c) Repeat (a) and (b) until the disc has been installed on the 4 remaining hub positions.
^If the minimum runout recorded in (a) to (c) is less than the maximum disc runout, install the disc in that position.
^ If the minimum runout recorded in (a) to (c) is greater than the maximum disc runout, replace the disc and repeat step 3.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows.

INSTALLATION
Installation is in the reverse order of removal.

HINT:
- After installation, fill the brake reservoir with brake fluid and bleed brake system.
- Check for leaks.