Assembly

WARNING:
- Never use an air hose or dry brush to clean brake assemblies.
- Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.
- Contaminated brake discs or pads reduce stopping ability.
- When reusing the pads, install them in their original positions to prevent loss of braking efficiency.

CAUTION:
- Do not spill brake fluid on the vehicle; It may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
- Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
- Before reassembling, check that all parts are free of dust and other foreign particles.
- Replace parts with new ones whenever specified to do so.
- Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
- Always use Genuine Honda DOT 3 Brake fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.

1. Pack all cavities of the needle bearing with the recommended rubber grease in the caliper seal set.





2. Coat a new cam boot with recommended rubber grease in the caliper seal set, and install it in the caliper body.
3. Apply recommended rubber grease in the caliper seal set to the pin contacting area of the cam, and install the cam and lever assembly into the caliper body.
4. Install the return spring.

CAUTION:
- When the cam and lever were separated, be sure to assemble them before installing the cam in the caliper body. Install the lever and spring washer, apply locking agent to the threads, and tighten the parking nut while holding the lever with a vise.
- Avoid damaging the cam boot since it must be installed before the cam.
- When installing the cam, do not allow the cam boot lips to turn outside in.





5. Install the pin in the cam.
6. Install a new O-ring on the sleeve piston.
7. Install the sleeve piston so that the hole in the bottom of the piston is aligned with the pin in the cam, and the two pins on the piston are aligned with the holes in the caliper.





8. Coat a new cup with recommended rubber grease in the caliper seal set, and install it with its groove facing the bearing A side of the adjusting bolt.
9. Fit the bearing A, spacer, adjusting spring B. and spring cover on the adjusting bolt, and install them in the caliper cylinder.





10. Install the special tool onto the spring cover, and turn the shaft until the locknut contacts the plate.
11. Check that the flared end of the spring cover is below the circlip groove.





12. Install the circlip into the groove, then remove the special tool.

NOTE: Check that the circlip is seated in the groove properly.





13. Coat a new piston seal with recommended silicone grease in the caliper seal set, and install it in the caliper.
14. Apply recommended rubber grease in the caliper seal set to the sealing lips and inside of a new piston boot, and install it in the caliper.





15. Coat the outside of the piston with brake fluid, and install it onto the adjusting bolt while rotating it clockwise with the tool.

CAUTION: Avoid damaging the piston and piston boot.





16. Install the pad spring onto the caliper.
17. Apply the recommended pin grease in the caliper seal set to the sliding surface of the pins and inside of the new pin boots.





18. Install the pin boots into the grooves in the caliper bracket properly.
19. Insert pin A and pin B into the caliper bracket.
20. Install the pin boots into the grooves in the pins properly.
21. Install the brake pad retainers and brake pads.
22. Align the cutout in the piston with the tab on the inner pad.





23. Install the caliper onto the caliper bracket, and tighten the caliper mounting bolts.
24. Connect the brake hose to the caliper with new sealing washers, and tighten the banjo bolt.





25. Insert the cable through the arm, and connect the cable to the lever with the clevis pin and lock pin. Install the cable clip securely.
26. Install the caliper shield.
27. Fill the brake reservoir, and bleed the brake system.
28. Operate the brake pedal several times, then adjust the parking brake.
29. After installation, perform the following checks:
- Check for leaks at hose and line joints and connections, and retighten if necessary.
- Check the parking brake lever for operation, and adjust it if necessary.
- Check for brake hose for interference or twisting.