Disassembly and Assembly
DISASSEMBLY
1. REMOVE DUST BOOT AND SLIDING BUSHING
a. Pull out the sliding bush with long-nose pliers by pushing it with a finger.
b. Remove the dust boot.
2. REMOVE MAIN PIN BOOT
Using a small screwdriver and a hammer, tap out the dust boot.
3. REMOVE CYLINDER BOOT SET RING AND CYLINDER BOOT
Using a small screwdriver, pry out the cylinder boot set ring and cylinder boot.
4. REMOVE PISTON FROM CYLINDER
Using SST, turn the piston counterclockwise and remove it.
SST 09719-14020 (09719-00020)
5. REMOVE PISTON SEAL FROM CYLINDER
Using a small screwdriver, pry out the piston seal.
6. REMOVE ADJUSTING BOLT ASSEMBLY
a. Set SST onto the adjusting bolt, and lightly tighten it with a 14 mm deep socket.
SST 09756-00010
CAUTION:
^ To insure safety, always use SST as there is a possibility of the spring flying out, causing injury or damaging to the interior surface of the cylinder.
^ Be careful not to tighten the SST too tightly as this may damage the spring retainer.
b. Using snap ring pliers, remove the snap ring from the cylinder.
c. Remove the parking brake strut, spring retainer, spring, spring plate and stopper together with the adjusting bolt from the cylinder.
7. DISASSEMBLE ADJUSTING BOLT ASSEMBLY
a. Remove the SST.
SST 09756-00010
b. Remove the spring retainer, spring, spring seat and stopper from the adjusting bolt.
c. Remove the O-ring from the adjusting bolt.
8. REMOVE TORSION SPRING FROM PARKING BRAKE CRANK
Using a small screwdriver, pry out the torsion spring.
9. REMOVE PARKING BRAKE CRANK FROM BRAKE CALIPER
10. REMOVE PARKING BRAKE CRANK BOOT
Using a small screwdriver and a hammer, tap out the parking brake crank boot.
11. REMOVE BLEEDER PLUG
12. REMOVE BOLT AND CABLE SUPPORT BRACKET
13. REMOVE STOPPER PIN
Using a pin punch and a hammer, tap out the stopper pin.
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 10.0 mm (0.394 inch)
Minimum thickness: 1.0 mm (0.039 inch)
Replace the pad if the pad's thickness is at the minimum thickness or less, or if the pad has severe, uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 16.0 mm (0.630 inch)
Minimum thickness: 15.0 mm (0.591 inch)
Replace the disc if the disc's thickness is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure disc runout at a position 10 mm (0.39 inch) from the outside edge.
Maximum disc runout: 0.10 mm (0.0039 inch)
If the disc's runout is at the maximum value or greater, check the bearing play is in the axial direction and check the axle hub runout. If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a "On-Car" brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
a. Remove the 2 mounting bolts and torque plate from the knuckle.
b. Remove the hub nuts and the disc.
1) Reinstall the disc in the position turned 1/4 from its original position on the hub.
2) Install and torque the hub nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
3) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub.
c. Repeat b. until the disc has been installed on the 2 remaining hub positions.
d. If the minimum runout recorded in (b) and (c) is less than 0.10 mm (0.0039 inch), install the disc in that position.
e. If the minimum runout recorded in (b) and (c) is greater than 0.10 mm (0.0039 inch), replace the disc and repeat step 3.
f. Install the torque plate and torque the 2 mounting bolts.
Torque: 59 Nm (600 kgf-cm, 44 ft. lbs.)
REASSEMBLY
1. INSTALL STOPPER PIN
Tap in the pin to the brake cylinder until the stopper pin extends 25 mm (0.98 inch).
2. INSTALL CABLE SUPPORT BRACKET WITH BOLT
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
3. INSTALL BLEEDER PLUG
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)
4. INSTALL PARKING BRAKE CRANK BOOT
a. Using SST and a hammer, tap in new parking brake crank boot shown in the illustration.
SST 09612-22011
b. Confirm that the metal plate portion of the parking brake crank boot fits snugly in the caliper.
5. INSTALL PARKING BRAKE CRANK
a. Check that the needle roller bearing is not covering the cylinder hole.
b. Install the parking brake crank in the caliper.
c. Check that there is clearance between the parking brake crank and caliper.
Standard clearance: 0.38 - 1.02 mm (0.0150 - 0.0416 inch)
6. INSTALL TORSION SPRING
Using a small screwdriver, install the torsion spring.
7. INSTALL NEW O-RING TO ADJUSTING BOLT
8. INSTALL ADJUSTING BOLT ASSEMBLY
a. Assemble the parking brake stopper, spring seat, spring, spring retainer and parking brake strut to the adjusting bolt, and using SST, fully tighten them down by hand.
SST 09756-00010
HINT:
^ Position the inscribed surface of the stopper upward.
^ Align the notches of the spring retainer and stopper.
b. Install the adjusting bolt assembly into the cylinder.
c. Using snap ring pliers, install the snap ring.
HINT: Face the snap ring opening toward the bleeder side.
d. Remove the SST.
SST 09756-00010
e. Firmly pull up the adjusting bolt by hand and insure that it does not move.
9. CHECK PARKING BRAKE CRANK OPERATION
Move the parking brake crank by hand and insure that the adjusting bolt moves smoothly.
10. INSTALL PISTON SEAL IN CYLINDER
11. INSTALL PISTON IN CYLINDER
Using SST, slowly turn the piston clockwise until the piston turns freely, then align the cylinder protrusion and piston stopper groove.
SST 09719-14020 (09719-00020)
12. INSTALL CYLINDER BOOT AND SET RING IN CYLINDER
13. INSTALL MAIN PIN BOOT
a. Using SST and a hammer, tap in a new main pin boot to the caliper.
SST 09325-12010
b. Confirm that the metal plate portion of the main pin boot fits snugly in the caliper.
14. INSTALL DUST BOOT AND SLIDING BUSHING
a. Install the dust boot.
b. Install the bushing into the boot with the flange facing inside.