Front Brake Installation

Align the matchmarks of the disc and axle hub, and install the disc.

NOTICE:

When replacing the disc with a new one, select the installation position where the front disc has the minimal runout.

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

Torque:

107 N*m{1089 kgf*cm, 79 ft.*lbf}

Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots.

HINT:

Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to each front disc brake bushing dust boot.

Install the 2 front disc brake bushing dust boots to the disc brake cylinder mounting.

Apply a light layer of lithium soap base glycol grease to the contact surface of the No. 2 front disc brake cylinder slide pin.

Install a new front disc brake cylinder slide bushing to the No. 2 front disc brake cylinder slide pin.

Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin.

Install the No. 1 front disc brake cylinder slide pin and No. 2 front disc brake cylinder slide pin to the cylinder mounting.

Install the 2 No. 1 front disc brake pad support plates and 2 No. 2 front disc brake pad support plates to the front disc brake cylinder mounting.

NOTICE:

Be sure to install each front disc brake pad support plate in the correct position and direction.

Apply disc brake grease to both sides of each No. 1 anti-squeal shim.

NOTICE:

1. When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
   
2. Install the shims in the correct positions and directions.
   
3. Apply disc brake grease to the area that contacts the anti-squeal shims.
   
4. Disc brake grease can seep out slightly from the area where the anti-squeal shim is installed.
   
5. Make sure that disc brake grease is not applied onto the lining surface.
   

Install the No. 1 anti-squeal shim and No. 2 anti-squeal shim to each brake pad.

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

NOTICE:

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

Hold the front disc brake cylinder slide pin and install the disc brake cylinder assembly to the disc brake cylinder mounting with the 2 bolts.

Torque:

34 N*m{347 kgf*cm, 25 ft.*lbf}

Connect the front flexible hose to the disc brake cylinder assembly with the union bolt and a new gasket.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

HINT:

Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

Fill the reservoir with brake fluid.

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

NOTICE:

Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

Connect a vinyl tube to the bleeder plug.

Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed*1.

When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal*2.

Repeat *1 and *2 until all the air in the fluid is completely bled out.

Tighten the bleeder plug completely.

Torque:

Front bleeder plug:

8.3 N*m{85 kgf*cm, 73 in.*lbf}

Rear bleeder plug (for Drum Brake):

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Rear bleeder plug (for Disc Brake):

10 N*m{102 kgf*cm, 7 ft.*lbf}

Repeat the above procedure for each wheel to bleed the brake line.

Check the fluid level.
If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3