BRAKE ACTUATOR(for RHD) REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   PRECAUTION

   Note:

   After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. Click here

   DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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3. Click here

   REMOVE FRONT WHEEL RH

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4. Click here

   DRAIN BRAKE FLUID

   Note:

   If brake fluid leaks onto any painted surface, immediately wash it off.

5. Click here

   REMOVE FRONT UPPER SUSPENSION TO COWL BRACE RH

   Tip:

   Use the same procedure for the RH side and LH side.

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6. Click here

   SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY

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7. Click here

   REMOVE WIRING HARNESS CLAMP BRACKET

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8. Click here

   REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

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9. Click here

   REMOVE BRAKE MASTER CYLINDER O-RING

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10. Click here

    REMOVE FRONT NO. 2 BRAKE TUBE

    
    
    1. 

       *a	From 1st Chamber of Brake Master Cylinder Sub-assembly
       *b	From 2nd Chamber of Brake Master Cylinder Sub-assembly
       *c	To Front Wheel Cylinder Assembly RH
       *d	To Front Wheel Cylinder Assembly LH
       *e	To Rear Wheel Cylinder Assembly RH
       *f	To Rear Wheel Cylinder Assembly LH

       Use tags or make a memo to identify the places to reconnect the brake lines.

    2. 

       Using a union nut wrench, disconnect the front No. 2 brake tube from the brake actuator assembly.

    3. Disengage the clamp.

    4. 

       *1	Front Flexible Hose
       *2	Grommet

       Using a union nut wrench, disconnect the front No. 2 brake tube from the front flexible hose.

    5. Disengage the grommet and remove the front No. 2 brake tube.

       Note:
       

       • Do not kink or damage the front No. 2 brake tube.

       • Do not allow any foreign matter such as dirt or dust to enter the front No. 2 brake tube from the connecting parts.

11. Click here

    REMOVE BRAKE ACTUATOR WITH BRACKET

    
    
    1. 

       	Release the lock lever
       	Disconnect the connector

       Release the lock lever and disconnect the connector from the brake actuator assembly.

       Note:

       Be careful not to allow any brake fluid to enter the connector.

    2. 

       Using a union nut wrench, disconnect the 5 brake lines from the brake actuator assembly.

    3. 

       Remove the 2 bolts, nut and brake actuator with bracket.

       Note:
       

       • Do not damage the brake lines.

       • Do not hold the brake actuator assembly by the connector.

       Tip:

       Remove the brake actuator with bracket while avoiding the brake lines.

12. Click here

    REMOVE NO. 5 BRAKE ACTUATOR BRACKET

    
    
    1. 

       Remove the bolt and No. 5 brake actuator bracket.

13. Click here

    REMOVE BRAKE ACTUATOR ASSEMBLY

    
    
    1. 

       Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.

14. Click here

    REMOVE BRAKE ACTUATOR BOLT CUSHION

    
    
    1. 

       *1	Brake Actuator Case Collar
       *2	Brake Actuator Bolt Cushion

       Remove the 3 brake actuator case collars from the brake actuator bolt cushions.

    2. Remove the 3 brake actuator bolt cushions from the brake actuator bracket assembly.