Front Disc Brake Repair Procedures

Removal

1. 1
   Remove the front wheel and tire.

   Tightening torque: 88.3 ~ 108 N·m

2. 2
   Loosen the guide rod bolt (B) and rotate the caliper (A) upward so that it does not interfere.

   Tightening torque: 21.6 ~ 31 N·m

   

3. 3
   Replace the pad shim (D), pad retainers (C) and brake pads (B) in the caliper support (A).

   

4. 4
   Loosen the banjo bolt of the hose (B) and the caliper mounting bolts (C), then remove the front caliper assembly (A). Tightening torque: Brake hose to caliper (B): 24.5 ~ 29 N·m Caliper assembly to steering knuckle (C): 78.5 ~ 98 N·m

   

Replacement

1. 1
   Remove the brake hose bracket mounting bolt (A).

   

2. 2
   Loosen the guide rod bolt (B) and rotate the caliper (A) upward so that it does not interfere.

   Tightening torque: 21.6 ~ 31 N·m

   

3. 3
   Replace the pad shim (D), pad retainers (C) and brake pads (B) in the caliper support (A).

   

Inspection

1. 1
   Inspect the brake pads for wear and discoloration.
2. 2
   Inspect the brake disc for damage and cracks.
3. 3
   Remove all rust and contamination from the surface and measure the disc thickness at no fewer than 8 points at equal distances (5 mm) from the outer edge of the brake disc. Brake disc thickness - Standard: 28 mm (1.10 in.) - Service limit: 26.4 mm (1.04 in.) Thickness variation: less than 0.005 mm (0.0002 in.)

   

4. 4
   If wear exceeds the limit, replace the discs and pads as a set on both the left and right sides of the vehicle.
5. 5
   Inspect the pad wear. Measure the pad thickness and replace the pad if it is less than the specified value. Pad thickness Standard: 11 mm (0.43 in.) Maximum operating limit: 2.0 mm (0.0787 in.)
6. 6
   Make sure grease is applied to the sliding contact points, as well as to the abutment and metal backing, and check for damage.

   

7. 7
   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: 0.04 mm (0.00157 in.) or less (new)

   

8. 8
   If brake disc runout exceeds the limit, replace the disc, then measure the runout again.
9. 9
   If runout does not exceed the limit, install the brake disc rotated 180°, then inspect the brake disc runout again.
10. 10
    If runout cannot be corrected by changing the brake disc position, replace the brake disc.

Installation

1. 1
   Installation is the reverse of removal.
2. 2
   Use SST (09581-11000) when installing the brake caliper assembly.

   

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