FRONT BRAKE(for 16 inch Front Disc Brake 2WD) INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. INSTALL FRONT DISC


    1. A01SASOC01
      *a Matchmark

      Align the matchmarks and install the front disc.

      Tech Tips

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

  2. INSTALL FRONT DISC BRAKE BUSH DUST BOOT


    1. A01SAKEC01
      B00692L Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of a new front disc brake bush dust boot, and the entire inner circumference of both ends.

      Tech Tips

      Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the front disc brake bush dust boot.

      Note

      Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the front disc brake bush dust boot and front disc brake cylinder mounting LH contact surfaces.

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

  3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH


    1. A01SE9EC01
      B00692L Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin where it contacts the front disc brake cylinder slide bush.

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

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. A01SANMC01
      B00692L Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the front disc brake cylinder slide pin.

    2. Install the front disc brake cylinder slide pin to the front disc brake cylinder mounting LH.

    3. Push the front disc brake cylinder slide pin into the front disc brake bush dust boot to align them.

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


    1. A01SCSKC01
      B00692L Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the sliding part and the seal surface of the No. 2 disc brake cylinder slide pin.

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

    3. Push the No. 2 disc brake cylinder slide pin into the front disc brake bush dust boot to align them.

  6. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH


    1. Install the front disc brake cylinder mounting LH with the 2 bolts.

      Torque:
      160 N*m  { 1632 kgf*cm, 118 ft.*lbf }

  7. INSTALL NO. 1 PAD SUPPORT PLATE


    1. A01SBTMC01
      *1 No. 1 Pad Support Plate
      *2 No. 2 Pad Support Plate

      Install the 2 No. 1 pad support plates to the front disc brake cylinder mounting LH.

      Note


      • The shapes of the pad support plates differ. Therefore, when replacing a pad support plate with a new plate, make sure to check the part number and shape for the installation position prior to installation.

      • When reusing a pad support plate, make sure to check the installation position using the matchmark placed during removal prior to installation.

  8. INSTALL NO. 2 PAD SUPPORT PLATE


    1. Install the 2 No. 2 pad support plates to the front disc brake cylinder mounting LH.

      Note


      • The shapes of the pad support plates differ. Therefore, when replacing a pad support plate with a new plate, make sure to check the part number and shape for the installation position prior to installation.

      • When reusing a pad support plate, make sure to check the installation position using the matchmark placed during removal prior to installation.

  9. INSTALL PAD WEAR INDICATOR PLATE


    1. Install the pad wear indicator plate to the inner lower side of the front disc brake pad.

      Note

      Install the pad wear indicator plate in the correct position and direction.

  10. INSTALL FRONT ANTI-SQUEAL SHIM KIT


    1. A01SDL5C01
      *1 Front Disc Brake Pad
      *2 No. 1 Anti-squeal Shim

      Install the 2 No. 1 anti-squeal shims to the front disc brake pads.

      Note

      When replacing a worn pad, the shims must be replaced together with the pads.

  11. INSTALL FRONT DISC BRAKE PAD


    1. Install the 2 front disc brake pads with the 2 No. 1 anti-squeal shims to the disc brake cylinder mounting LH.

      Note

      Make sure there is no oil or grease on the friction surfaces of the front disc brake pads and front disc.

    2. A01SDE3

      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.

  12. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH


    1. A01SDPUC01
      *a Hold
      *b Turn

      Hold the front disc brake cylinder slide pin and install the disc brake cylinder assembly LH to the disc brake cylinder mounting LH with the 2 bolts.

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

      Note


      • Install the disc brake cylinder assembly LH 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.

  13. CONNECT FRONT FLEXIBLE HOSE


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

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

      Tech Tips

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

  14. BLEED BRAKE LINE (w/ VSC)

    Click here

  15. BLEED BRAKE LINE (w/o VSC)

    Click here

  16. BLEED CLUTCH LINE (for Manual Transmission)

    Click here

  17. INSTALL FRONT WHEEL

    Click here