Professional Documents
Culture Documents
BRAKE (FRONT) FRONT BRAKE(for 16 inch Front Disc Brake 2WD) INSTALLATION
HINT:
· Use the same procedure for the RH and LH sides.
· The procedure listed below is for the LH side.
PROCEDURE
a.
*a Matchmark
a.
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.
HINT:
Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the front disc brake bush dust boot.
NOTICE:
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.
b. Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
a.
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.
b. Install a new front disc brake cylinder slide bush to the No. 2 front disc brake cylinder slide pin.
a.
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.
b. Install the front disc brake cylinder slide pin to the front disc brake cylinder mounting LH.
c. Push the front disc brake cylinder slide pin into the front disc brake bush dust boot to align them.
a.
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.
b. Install the No. 2 disc brake cylinder slide pin to the front disc brake cylinder mounting LH.
c. Push the No. 2 disc brake cylinder slide pin into the front disc brake bush dust boot to align them.
a. Install the front disc brake cylinder mounting LH with the 2 bolts.
Torque:
160 N*m (1632 kgf*cm, 118 ft.*lbf)
a.
Install the 2 No. 1 pad support plates to the front disc brake cylinder mounting LH.
NOTICE:
· 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.
a. Install the 2 No. 2 pad support plates to the front disc brake cylinder mounting LH.
NOTICE:
· 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.
a. Install the pad wear indicator plate to the inner lower side of the front disc brake pad.
a.
Install the 2 No. 1 anti-squeal shims to the front disc brake pads.
NOTICE:
When replacing a worn pad, the shims must be replaced together with the pads.
a. Install the 2 front disc brake pads with the 2 No. 1 anti-squeal shims to the disc brake cylinder mounting LH.
NOTICE:
Make sure there is no oil or grease on the friction surfaces of the front disc brake pads and front disc.
b.
a.
*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)
NOTICE:
· 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.
a. 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)