FRONT BRAKE(for 16 inch Front Disc Brake) INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL FRONT DISC


    1. A01UFA2C02
      *a Matchmark

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

      Note

      When replacing the front disc with a new one, select the installation position where the front disc has minimal runout.

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


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

      Torque:
      106.8 N*m  { 1089 kgf*cm, 79 ft.*lbf }

  3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT


    1. A01UD1QC02
      B006PCE 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 more than 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 DISC BRAKE CYLINDER SLIDE PIN


    1. A01UDCAC01
      B006PCE Lithium Soap Base Glycol Grease

      Apply a light layer of lithium soap base glycol grease to the contact surface of the front disc brake cylinder slide pin (lower).

    2. Install a new front disc brake cylinder slide bushing to the front disc brake cylinder slide pin (lower).

    3. A01UFF1C01
      B006PCE 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 2 front disc brake cylinder slide pins.

    4. Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting.

    5. Push the 2 front disc brake cylinder slide pins into the front disc brake bushing dust boot to engage the pins to the boots.

  5. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE


    1. A01UDKRC02
      *1 Front No. 1 Disc Brake Pad Support Plate
      *2 Front No. 2 Disc Brake Pad Support Plate
      *a Claw

      Install the 2 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.

  6. INSTALL FRONT ANTI-SQUEAL SHIM KIT

    Note


    • When replacing worn front disc brake pads, the front disc brake anti-squeal shims and front disc brake pad wear indicator plate must be replaced together with the front disc brake pads.

    • Do not apply disc brake grease to the lining surface of the brake pad.

    • Install the front disc brake pad wear indicator plate in the correct position and direction.

    • Install the front disc brake anti-squeal shims in the correct position and direction.


    1. A01UE4XC01
      B006REL Disc Brake Grease

      Apply disc brake grease to both sides of each front No. 1 disc brake anti-squeal shim as shown in the illustration.

    2. A01UD8HC02
      *1 Front No. 1 Disc Brake Anti-squeal Shim
      *2 Front No. 2 Disc Brake Anti-squeal Shim
      *3 Front Disc Brake Pad Wear Indicator Plate

      Install the front No. 1 disc brake anti-squeal shim and front No. 2 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 (inside).

  7. INSTALL FRONT DISC BRAKE PAD


    1. Install the 2 front disc brake pads to the front disc brake cylinder mounting.

      Note


      • Install the front disc brake pad with the pad wear indicator plate is mounted on the inner side of the vehicle.

      • Install the front disc brake pad so that the pad wear indicator plate is mounted on the upper side of the vehicle.

  8. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY


    1. 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 }

  9. 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:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

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

  10. BLEED BRAKE LINE

    Click here

  11. INSTALL FRONT WHEEL

    Click here