FRONT BRAKE INSTALLATION

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


  1. INSTALL FRONT DISC


    1. A01GEHVC01
      *a Matchmark

      Align the matchmarks of the front disc and front axle hub sub-assembly, and install the front disc.

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts.

      Torque:
      104 N*m  { 1061 kgf*cm, 77 ft.*lbf }
  3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT


    1. A01GEQBC06
      B004057 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.

    2. Install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.

  4. INSTALL FRONT NO. 2 DISC BRAKE CYLINDER SLIDE PIN


    1. A01GF33C01
      B004057 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.

    2. Install a new front disc brake cylinder slide bushing to the front No. 2 disc brake cylinder slide pin.

    3. A01GF0CC01
      B004057 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.

    4. Install the front No. 2 disc brake cylinder slide pin to the front disc brake cylinder mounting.

    5. 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.

  5. INSTALL FRONT NO. 1 DISC BRAKE CYLINDER SLIDE PIN


    1. A01GF39C01
      B004057 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.

    2. Install the front No. 1 disc brake cylinder slide pin to the front disc brake cylinder mounting.

    3. 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.

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. A01GERVC01
      *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.

  7. 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.


    1. A01GEGTC01
      B004057 Disc Brake Grease

      Apply disc brake grease to the inside of each front disc brake anti-squeal shim as shown in the illustration.

    2. A01GELMC01
      *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.

    3. Install the front disc brake pad wear indicator plate to each front disc brake pad.

  8. INSTALL FRONT DISC BRAKE PAD


    1. 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.

    2. A018HZM

      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.

  9. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY


    1. 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.

      Torque:
      34.3 N*m  { 350 kgf*cm, 25 ft.*lbf }

      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.

  10. CONNECT FRONT FLEXIBLE HOSE


    1. Connect the front flexible hose to the front disc brake cylinder assembly with a new union bolt and a new gasket.

      Torque:
      30.4 N*m  { 310 kgf*cm, 22 ft.*lbf }

      Note

      Install the front flexible hose lock securely into the lock hole in the front disc brake cylinder assembly.

  11. BLEED BRAKE LINE

    Click here

  12. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }