Front Disc Brake Repair Procedures

Removal

1. 1
   Remove the front wheel and tire.

   Tightening torque: 88.3 ~ 108 N·m

2. 2
   Remove the brake hose mounting bracket (A).

   

3. 3
   Remove the shim (A) by loosening the bolts.

   Tightening torque 7.8 ~ 10.8 N·m

   

   Apply the specified torque using a torque wrench. Do not use a pneumatic impact wrench or power tools.

4. 4
   Remove the stopper pin (A) and guide pin (B).

   

5. 5
   Remove the brake pad.

   

   Do not depress the brake pedal.

6. 6
   Loosen the hose union bolt (C) and caliper mounting bolts (A), then remove the front caliper assembly (B). Tightening torque: Brake hose to caliper (C): 24.5 ~ 29 N·m Caliper assembly to steering knuckle (A): 98.1 ~ 118 N·m

   

   Do not loosen the hose union bolt (C) when replacing the rear disc. After loosening the rear brake caliper mounting bolts (A), secure the rear brake caliper to other components with wire.

7. 7
   Loosen the hub nut (A) and screw (B), then remove the disc. Tightening torque A: 196.1 ~ 275 N·m B: 4.9 ~ 5.9 N·m

   

8. 8
   Remove the front wheel and tire.

   Tightening torque: 88.3 ~ 108 N·m

9. 9
   Loosen the guide rod bolt (B) and swing the caliper aside.

   Tightening torque: 21.6 ~ 31 N·m

   

10. 10
    Remove the pad shim (B), pad retainers (C), and brake pads (B) from the caliper bracket (A).

    

    Do not depress the brake pedal.

11. 11
    Loosen the hose union bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

    

    Do not loosen the hose union bolt (B) when replacing the rear disc. After loosening the rear brake caliper mounting bolts (C), secure the rear brake caliper to other components with wire.

12. 12
    Remove the front brake disc by loosening the screws (3 pcs).

    

Replacement

[4-Piston Type]

1. 1
   Remove the shim (A) by loosening the bolts.

   Tightening torque: 7.8 ~ 10.8 N·m

   

   Apply the specified torque using a torque wrench. Do not use a pneumatic impact wrench or power tools.

2. 2
   Remove the stopper pin (A) and guide pin (B).

   

3. 3
   Remove the brake pad.

   

   Do not depress the brake pedal.

4. 4
   Inspect the brake pads for wear and discoloration.
5. 5
   Inspect the brake disc for damage and cracks.
6. 6
   Remove all rust and contamination from the surface and measure the disc thickness at no fewer than 8 points at equal intervals (5 mm) from the outer edge of the brake disc. Brake disc thickness Standard: 30 mm (1.1811 in.) Service limit: 28.4 mm (1.1181 in.)

   

7. 7
   Check pad wear. Measure the pad thickness and replace the pads if they are less than the specified value. Pad thickness Standard (A): 10.5 mm (0.4133 in.) Wear limit (B): 2.0 mm (0.0787 in.)

   

   The pad wear indicator (C) and brake disc create squealing noise when the brake pads wear below the service limit of 2.0 mm (B).

8. 8
   Position a dial indicator approximately 5 mm (0.2 in.) from the outer edge of the brake disc and measure the disc runout.

   Brake disc runout Limit: 0.025 mm (0.00098 in.) or less (new)

   

9. 9
   If the brake disc runout exceeds the specification, reinstall the disc by rotating it 72° clockwise. Recheck the runout. If the runout still exceeds the specification, rotate the disc 72° at a time and recheck the runout until a full turn (360°, 4 steps) is completed.
10. 10
    If the runout cannot be corrected by rotating the disc, replace the brake disc.
11. 11
    When installing the brake disc, position the runout high points (A) on the disc and hub as close together as possible (within a 72° range).
12. 12
    After installing a new disc, repeat steps 1 through 4 above.

Installation

1. 1
   To install, reverse the removal procedure.
2. 2
   Use SST (A: 09581-11000) when installing the brake caliper assembly.

   

   

3. 3
   After installation, bleed the brake system. (Refer to Brake System - Brake System Bleeding)