CAUTION / NOTICE / HINT
Tech Tips
Use the same procedure for the LH side and RH side.
The following procedure is for the LH side.
PROCEDURE
INSTALL FRONT DISC
*a | Matchmark |
Align the matchmarks of the front disc and front axle hub sub-assembly, and install the front disc.
INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.
INSTALL FRONT DISC BRAKE BUSHING DUST BOOT
Lithium Soap Base Glycol Grease |
Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.
Tech Tips
Apply at least 0.3 g (0.01 oz) of lithium soap base glycol grease to each front disc brake bushing dust boot.
Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.
INSTALL FRONT NO. 2 DISC BRAKE CYLINDER SLIDE PIN
Lithium Soap Base Glycol Grease |
Apply a light layer of lithium soap base glycol grease to the contact surface of the front No. 2 disc brake cylinder slide pin.
Install a new front disc brake cylinder slide bushing to the front No. 2 disc brake cylinder slide pin.
Lithium Soap Base Glycol Grease |
Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the front No. 2 disc brake cylinder slide pin.
Install the front No. 2 disc brake cylinder slide pin to the front disc brake cylinder mounting.
Push the front No. 2 disc brake cylinder slide pin into the front disc brake bushing dust boot to engage the pin to the boot.
INSTALL FRONT NO. 1 DISC BRAKE CYLINDER SLIDE PIN
Lithium Soap Base Glycol Grease |
Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the front No. 1 disc brake cylinder slide pin.
Install the front No. 1 disc brake cylinder slide pin to the front disc brake cylinder mounting.
Push the front No. 1 disc brake cylinder slide pin into the front disc brake bushing dust boot to engage the pin to the boot.
INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
*1 | Front No. 1 Disc Brake Pad Support Plate |
*2 | Front No. 2 Disc Brake Pad Support Plate |
*3 | Front No. 3 Disc Brake Pad Support Plate |
*4 | Front No. 4 Disc Brake Pad Support Plate |
*a | Protrusion |
Install the 4 front disc brake pad support plates to the front disc brake cylinder mounting.
Note
Be sure to install each front disc brake pad support plate in the correct position and direction.
Tech Tips
The front disc brake pad support plate (lower) can be identified by its protrusion.
INSTALL FRONT DISC BRAKE ANTI-SQUEAL SHIM KIT
Note
When replacing worn front disc brake pads, the front disc brake anti-squeal shim kit must be replaced together with the front disc brake pads.
Make sure that disc brake grease is not applied onto the lining surface.
Install each front disc brake pad wear indicator plate in the correct position and direction.
Install the front disc brake anti-squeal shims in the correct positions and directions.
Disc Brake Grease |
Apply disc brake grease to the inside of each front disc brake anti-squeal shim as shown in the illustration.
*1 | Front Disc Brake Anti-squeal Shim |
*2 | Front Disc Brake Pad Wear Indicator Plate |
Install the front disc brake anti-squeal shim to each front disc brake pad.
Install the front disc brake pad wear indicator plate to each front disc brake pad.
INSTALL FRONT DISC BRAKE PAD
Install the 2 front disc brake pads to the front disc brake cylinder mounting.
Note
There should be no oil or grease on the friction surfaces of the front disc brake pads or the front disc.
Install the 2 anti-squeal springs to the front disc brake pads.
Note
When replacing the front disc brake pads with new ones, make sure to replace the anti-squeal springs at the same time.
Be sure to install the anti-squeal springs into the front disc brake pad installation holes as far as they will go.
INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY
Hold each front disc brake cylinder slide pin and install the front disc brake cylinder assembly to the front disc brake cylinder mounting with the 2 bolts.
Note
Install the front disc brake cylinder assembly while holding both of the front disc brake pads because the anti-squeal springs may fall off the front disc brake pads.
Be sure that the anti-squeal springs are installed to the front disc brake pads.
CONNECT FRONT FLEXIBLE HOSE
Connect the front flexible hose to the front disc brake cylinder assembly with a new union bolt and a new gasket.
Note
Install the front flexible hose lock securely into the lock hole in the front disc brake cylinder assembly.
BLEED BRAKE LINE
INSTALL FRONT WHEEL