FRONT BRAKE DISASSEMBLY


  1. REMOVE FRONT DISC BRAKE PAD KIT


    1. Remove the 2 brake pads with anti-squeal shims.

  2. REMOVE FRONT DISC BRAKE ANTI SQUEAL SHIM KIT


    1. Remove the 4 anti-squeal shims from the brake pad.

    2. Remove the pad wear indicator from each pad.

  3. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE

  4. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE

  5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. Remove the cylinder slide pin from the cylinder mounting.

  6. REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH


    1. A003BWTE01

      Using a screwdriver, remove the cylinder slide bush from the cylinder slide pin.

      Tech Tips

      Tape the screwdriver tip before use.

  7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN NO.2


    1. Remove the cylinder slide pin No.2 from the cylinder mounting.

  8. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING


    1. Remove the 2 bolts and cylinder mounting.

  9. REMOVE BUSH DUST BOOT NO.1


    1. Secure the cylinder mounting in a vise.

    2. A003CI9

      Using a screwdriver and a plastic hammer, remove the 2 bush dust boots.

  10. REMOVE CYLINDER BOOT


    1. A003DK1

      Using a screwdriver, remove the set ring.

      Note

      Do not damage the inner cylinder or cylinder groove.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the cylinder boot.

  11. REMOVE FRONT DISC BRAKE PISTON


    1. A003AM6

      Place a shop rag or a piece of cloth between the piston and the disc brake cylinder assembly.

    2. Use compressed air to remove the piston from the disc brake cylinder assembly.

      CAUTION:

      Do not place your fingers in front of the piston when using compressed air.

      Note

      Do not spatter the brake fluid.

  12. REMOVE PISTON SEAL


    1. A003B2W

      Using a screwdriver, remove the piston seal from the disc brake cylinder assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP

  14. REMOVE FRONT DISC BRAKE BLEEDER PLUG

  15. SEPARATE FRONT SPEED SENSOR


    1. A003ICLE01

      Remove the 2 bolts, and separate the speed sensor from the steering knuckle.

      Note


      • Be careful not to damage the speed sensor.

      • Prevent foreign matter from adhering to the speed sensor.

  16. SEPARATE TIE ROD END SUB-ASSEMBLY


    1. Remove the cotter pin and castle nut.

    2. A003B6SE01

      Using SST, separate the tie rod end from the steering knuckle.

      SST
      09628-00011

      Note


      • Do not damage the ball joint dust boot.

      • Do not damage the brake dust cover.

      • Make sure that the string of the SST is securely tied to the vehicle.

  17. REMOVE FRONT AXLE ASSEMBLY


    1. A003EK2

      Remove the 4 bolts, 4 nuts and front axle assembly from the front suspension lower arm.

    2. Remove the cotter pin and castle nut.

    3. A003DTZE01

      Using SST, remove the front axle assembly from the front suspension upper arm.

      SST
      09628-62011

      Note


      • Do not damage the ball joint dust boot.

      • Apply grease to the threads and tip of the SST center bolt before use.

      • Make sure that the string of the SST is securely tied to the vehicle.

  18. REMOVE FRONT LOWER BALL JOINT ASSEMBLY


    1. Fix the steering knuckle in the vise using aluminium plates.

      Note

      Do not damage the steering knuckle.

    2. Remove the cotter pin.

    3. Loosen the nut.

    4. A003G89E01

      Using SST, separate the front lower ball joint assembly from the steering knuckle.

      SST
      09628-00011

      Note


      • Do not damage the ball joint dust boot.

      • Make sure that the string of the SST is securely tied to the steering knuckle.

    5. Remove the nut and front lower ball joint assembly.

  19. REMOVE INNER KNUCKLE GREASE RETAINER CAP (w/ Cap)


    1. A003C01

      Using a chisel, make a hole in the center of the outer knuckle grease retainer cap to insert a brass bar.

    2. A003B70

      Using a brass bar, remove the inner knuckle grease retainer cap from the steering knuckle as shown in the illustration.

  20. REMOVE OUTER KNUCKLE GREASE RETAINER CAP (w/ Cap)


    1. A003BPNE01

      Using SST, remove the outer knuckle grease retainer cap.

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07200 )

  21. REMOVE STEERING KNUCKLE


    1. A003DFNE01

      Remove the 4 bolts.

    2. A003ICAE01

      Using SST, remove the steering knuckle, brake dust cover from the front axle hub sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04010, 09958-04011 )
      09950-60010   ( 09951-00470 )
      09955-04140
      09958-04030

      Note


      • Apply grease to the threads and tip of the SST center bolt (09953-04010) before use.

      • Make sure that the slide arm (09952-04010) is at a 90° angle to the hanger 200 (09951-04020) when using SST.

      • Make sure that the claw No. 14 (09955-04140) is securely attached to the steering knuckle.

      Tech Tips

      For bolt A, use the bolt for the holder (09958-04011).

  22. REMOVE FRONT DISC


    1. A003CJ9E01

      Remove the 6 bolts.

    2. A003ASXE01

      Remove the front disc as shown in the illustration.