FRONT BRAKE INSTALLATION

CAUTION / NOTICE / HINT

Tip:

  • 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. C302514

      Using a T30 "TORX" socket wrench, install the front disc and temporarily tighten the hexalobular screw.

      Note:

      When replacing the front disc with a new one, confirm that the runout is within specification. If the runout of the new front disc exceeds the maximum value, replace the new front disc.

      Tip:

      The runout of the disc is offset or compounded by the runout of the front axle hub. If the runout of the new front disc exceeds the maximum value, replace it with one that matches the front axle hub.

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING

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

      88.3 N*m

      900 kgf*cm

      65 ft.*lbf

  3. INSTALL FRONT DISC BRAKE BUSHING DUST BOOT

    1. C224880C05
      V100155

      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.

      Tip:

      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 BUSHING

    1. C302510C01
      V100155

      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).

  5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN

    1. C302511C01

      *1

      Front Disc Brake Cylinder Slide Pin (Upper)

      *2

      Front Disc Brake Cylinder Slide Pin (Lower)
      V100155

      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.

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

      Note:

      Be sure to install each front disc brake cylinder slide pin in the correct position and direction.

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

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

    1. Install the 4 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.

      • When replacing the front disc brake pads with new ones, make sure to replace the front disc brake pad support plates at the same time.

  7. INSTALL FRONT DISC BRAKE PAD

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

      Note:

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

  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.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

  9. CONNECT FRONT FLEXIBLE HOSE

    Click here

  10. BLEED BRAKE LINE

    Click here

  11. FULLY TIGHTEN HEXALOBULAR SCREW

    1. C302503

      Using a T30 "TORX" socket wrench, fully tighten the hexalobular screw.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

      Note:

      Depress the brake pedal to prevent the front disc from rotating.

  12. INSTALL FRONT WHEEL

    Click here