REAR DISC BRAKE

BRAKE CALIPER ASSEMBLY : Removal and Installation

WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne particles or other materials.

CAUTION:

• While removing caliper, do not depress brake pedal because the piston will pop out.
• Do not damage piston boot.
• Keep disc rotor free from brake fluid.
• Refill the brake reservoir with new brake fluid "DOT 3".
• Never reuse drained brake fluid.

REMOVAL

1. Remove rear wheel and tires. Refer to See: Maintenance\Wheels and Tires\Service and Repair.
2. Fasten disc rotor using a wheel nut.
3. Drain brake fluid. Refer to See: Hydraulic System\Brake Fluid\Service and Repair\Removal and Replacement.

4. Remove union bolt (A) and then disconnect brake hose from caliper. Discard the copper washers.

CAUTION:
Do not reuse copper washers.

5. Remove the two torque member bolts (A), and then remove the torque member, caliper and pads as an assembly.

CAUTION:
Do not drop the brake pad and multilayered shim assemblies.

6. Remove the two sliding pin bolts and separate the caliper from the torque member. Remove the brake pad and multilayered shim assemblies from the caliper.

7. Remove the disc rotor.

CAUTION:
Put matching marks on wheel hub assembly and disc rotor, if it necessary to reuse the disc rotor.

INSTALLATION

1. Install the disc rotor.

2. Install the brake pad and multilayered shim assemblies on the caliper. Refer to See: Brake Pad\Service and Repair\Removal and Replacement\Rear\Exploded View.
3. Install the caliper and pad assembly on the torque member, then tighten the two sliding pin bolts to the specified torque.

4. Install the torque member, pads and brake caliper assembly, and tighten the torque member bolts (A) to the specified torque.

CAUTION:
Before installing wipe off all oil and moisture on all mating surfaces of rear axle and torque member, threads, bolts and washers.

5. Align the L-shaped pin on the brake hose in the hole in the caliper, then install the brake hose with new copper washers and tighten the union bolt to the specified torque. Refer to See: Hydraulic System\Brake Hose/Line\Service and Repair\Removal and Replacement\Brake Tube And Hose Rear Brake.

CAUTION:
Do not reuse copper washers.

6. Refill with new brake fluid and bleed air. Refer to See: Brake Bleeding\Service and Repair.
7. Check rear disc brake for drag.
8. Install rear wheel and tires. Refer to See: Maintenance\Wheels and Tires\Service and Repair.