FRONT BRAKE(for 15 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

INSTALL FRONT DISC
1. *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.
INSTALL FRONT DISC BRAKE BUSH DUST BOOT
1. 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.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
1. 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.
INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
1. 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.
INSTALL NO. 2 FRONT DISC BRAKE CYLINDER SLIDE PIN
1. 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.
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 }
INSTALL NO. 1 PAD SUPPORT PLATE
1. *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 front 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.
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.
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.

INSTALL FRONT ANTI-SQUEAL SHIM KIT

*a	Inner Pad
*b	Outer Pad
	Area for disc brake grease application

Apply disc brake grease to the inside of the 2 No. 1 anti-squeal shims as shown in the illustration.

Note

When replacing worn pads, the No. 1 anti-squeal shims must be replaced together with the pads.
Apply disc brake grease to the area that contacts the No. 1 anti-squeal shims.
Disc brake grease can come out slightly from the area where the No. 1 anti-squeal shims are installed.
Make sure that disc brake grease is not applied onto the lining surface.

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

Install the No. 1 anti-squeal shims and No. 2 anti-squeal shims to the pads.

Note

When replacing a worn pad, the shims must be replaced together with the pads.
Install the shims in the correct positions and directions as shown in the illustration.

INSTALL FRONT DISC BRAKE PAD
1. Install the 2 front disc brake pads to the front 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.
INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
1. *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 }
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.
BLEED BRAKE LINE (w/ VSC)

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BLEED BRAKE LINE (w/o VSC)

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BLEED BRAKE SYSTEM (w/o ABS)

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BLEED CLUTCH LINE (for Manual Transmission)

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INSTALL FRONT WHEEL

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

*a	Hold
*b	Turn