FRONT BRAKE INSTALLATION

Tech Tips

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

  • The following procedure is for the LH side.

  1. INSTALL FRONT DISC

    1. Align the matchmarks of the front disc and front axle hub, and install the front disc.

      A011UDHE01
      Text in Illustration
      *a Matchmark

      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 BUSHING DUST BOOT

    1. Secure the front disc brake cylinder mounting in a vise.

    2. Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.

      A011QYE
      Text in Illustration
      A011SIH Lithium Soap Base Glycol Grease

      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.

    3. Using a socket wrench (19 mm) and a hammer, install the 2 front disc brake bushing dust boots to the front disc brake cylinder mounting.

      A011TRB

  3. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

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

      A011V04
      Torque:
      107 N*m  { 1090 kgf*cm, 79 ft.*lbf }

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSHING

    1. Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.

      A011V5S
      Text in Illustration
      A011SIH Lithium Soap Base Glycol Grease

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

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

    1. 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.

      A011RHR
      Text in Illustration
      A011SIH Lithium Soap Base Glycol Grease

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

      A011SAS

    3. 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.

  6. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

    1. Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the front disc brake cylinder slide pin.

      A011R03
      Text in Illustration
      A011SIH Lithium Soap Base Glycol Grease

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

      A011R00

    3. Push the front disc brake cylinder slide pin into the front disc brake bushing dust boot to engage the pin to the boot.

  7. INSTALL FRONT DISC BRAKE FITTING KIT

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

      A011S5PE01
      Text in Illustration
      *1 Front No. 1 Disc Brake Pad Support Plate
      *2 Front No. 2 Disc Brake Pad Support Plate

      Note

      Be sure to install each front disc brake pad support plate in the correct position and direction.

  8. INSTALL FRONT ANTI-SQUEAL SHIM KIT

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

      A011UXK

      Note

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

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

      A011RSI
      Text in Illustration
      A011SIH Disc Brake Grease

    3. Install the front disc brake anti-squeal shim to each front disc brake pad.

      A011UI4

      Note

      • Install the front disc brake anti-squeal shims in the correct positions and directions.

      • Disc brake grease can seep out slightly from the area where the front disc brake anti-squeal shim is installed.

      • Make sure that disc brake grease is not applied onto the lining surface.

  9. INSTALL FRONT DISC BRAKE PAD KIT

    1. Install the 2 front disc brake pads with front anti-squeal shim kit to the front disc brake cylinder mounting.

      Note

      There should be no oil or grease on the friction surfaces of the disc brake pads or the front disc.

    2. Install the 2 anti-squeal springs to the front disc brake pads.

      A011R27

      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.

  10. INSTALL DISC BRAKE CYLINDER ASSEMBLY

    1. Hold the 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.

      A011ROPE01
      Text in Illustration
      *a Hold
      *b Turn
      Torque:
      34 N*m  { 350 kgf*cm, 25 ft.*lbf }

  11. CONNECT FRONT FLEXIBLE HOSE

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

      A011SR0E01
      Text in Illustration
      *a Lock Hole
      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

      Note

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

  12. BLEED BRAKE LINE

    Click here

  13. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }