Conventional Brake Components Acura TL III

Scheme 1

Scheme 2

Brake System Inspection and Test

Inspect the brake system components listed. Repair or replace any parts that are leaking or damaged.

Component Inspections

BRAKE SYSTEM COMPONENT INSPECTION TABLE

Brake pedal sinks/fades when braking

1. Start the engine, and let it warm up to operating temperature.
2. Attach a 50 mm (2 in.) piece of masking tape along the bottom of the steering wheel, and draw a horizontal reference mark across it.
3. With the transmission in Neutral, press and hold the brake pedal lightly (about the same pressure needed to keep an A/T-equipped vehicle from creeping), then release the parking brake.
4. While still holding the brake pedal, hook the end of the tape measure behind it. Then pull the tape up to the steering wheel, noting where the tape measure lines up with the reference mark you made on the masking tape.
5. Apply steady pressure to the brake pedal for 3 minutes.
6. Watch the tape measure. If it moves less than 10 mm (3/8 in.), the master cylinder is OK. If it moves more than 10 mm (3/8 in.), replace the master cylinder. NOTE: If the brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the brake booster.)

Rapid brake pad wear, vehicle vibration (after a long drive), or high, hard brake pedal

Note. For A/T model, make sure that the caliper pins are installed correctly.

The top and bottom caliper pins are different. If the top and bottom caliper pins are installed in the wrong location, it will cause uneven tire wear, vibration, and or uneven or rapid pad wear for proper caliper pin location (see FRONT BRAKE CALIPER OVERHAUL ).

1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more brake pedal applications during an extended test-drive.
2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand. Is there brake drag at any of the wheels? YES -Go to step 3. NO -Look for other causes of the pad wear, high pedal, or vehicle vibration.
3. Turn the engine off, pump the brake pedal to deplete the vacuum in the brake booster, and then spin the wheels again to check for brake drag. Is there brake drag at any of the wheels? YES -Go to step 4. NO -Replace the brake booster.
4. Without removing the brake lines, unbolt and separate the master cylinder from the booster, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES -Go to step 5. NO -Check the brake pedal position switch adjustment and pedal free play.
5. Loosen the hydraulic lines at the master cylinder, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES -Go to step 6. NO -Replace the master cylinder.
6. Loosen the breed screws at each caliper, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? YES -Disassemble and repair the caliper on the wheel(s) with brake drag. NO -Look for a bulging master cylinder cap seal, discolored or contaminated brake fluid in the master cylinder, or damaged brake lines. If any of these items are damaged, replace them. If all of these items are OK, replace the VSA modulator-control unit.

Scheme 3

Scheme 4

Scheme 5

1. Turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (B) from the left side middle of the pedal pad (C). Standard pedal height (with carpet removed): M/T: 171 mm (6 3/4 in.) A/T: 170 mm (6 11/16 in.)
3. Loosen the pushrod locknut (A), and screw the pushrod (B) in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Brake Pedal Position Switch Clearance
4. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 to 0.118 in.) by locking the switch. Make sure the brake lights go off when the pedal is released.
5. Check the brake pedal free play.

Scheme 6

1. With the engine off, inspect the play (A) on the brake pedal pad (B) by pushing the brake pedal by hand.
2. If the brake pedal free play is out of specification, adjust the brake pedal position switch (C). If the brake pedal free play is insufficient, it may result in excessive brake drag.

Scheme 7

1. Pull the parking brake lever (A) with 196 N (20 kgf, 44 lbf) of force to fully apply the parking brake. The parking brake lever should be locked within the specified number of clicks (B).
2. Adjust the parking brake if the lever clicks are not within the specification. NOTE: Minor parking brake lever adjustments (1 to 2 clicks) can be made with the adjusting nut in the equalizer. If a larger adjustment is required, follow the major adjustment procedure using the adjuster at the parking brake drum. After installing new parking brake shoes and/or new brake disc/drum, make sure you drive the vehicle for "break-in" (see «PARKING BRAKE SHOE LINING BREAK-IN»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__parking-brake-shoe-lining-break-in) ).

Scheme 8

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Release the parking brake lever fully.
3. Open the console box lid then remove the console mat.
4. Remove the lid to access the adjusting nut.
5. Pull the parking brake lever 1 click.
6. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
7. Release the parking brake lever fully, and check that the parking brakes do not drag when the rear wheels are turned. Readjust if necessary.
8. Make sure the parking brakes are fully applied when the parking brake lever is pulled all the way.
9. Reinstall the center console lid and console mat.

Scheme 9

Scheme 10

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Release the parking brake lever fully.
3. Open the console box lid then remove the console box mat.
4. Remove the lid to access the adjusting nut.
5. Back off the adjusting nut (A) in the equalizer.
6. Remove the rear wheels.
7. Remove the access plug (A).
8. Turn the ratchet teeth (B) on the adjuster assembly (C) with a flat-tip screwdriver (D) until the shoes lock against the parking brake drum. Then back off the adjuster 8 clicks, and install the access plug.
9. Do the minor adjustment procedure.
10. Install the rear wheels.
11. Reinstall the center console lid and console mat.

Brake System Bleeding

Note. Do not reuse the drained fluid. Use only clean ACURA DOT 3 Brake Fluid from an unopened container. Using a non-Acura brake fluid can cause corrosion and shorten the life of the system. Do not mix different brands of brake fluid; they may not be compatible. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 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. The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. Front caliper for the M/T model (4-piston caliper type); do this by first bleeding the outside piston of the front caliper. Then bleed the inside piston of the front caliper.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A).
2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid.
3. Have someone slowly pump the brake pedal several times, then apply steady pressure.
4. Loosen the left-front brake bleed screw, loosen the brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. NOTE: The bleed valve uses an 11 mm hex wrench on M/T model. On M/T model, bleed the outside piston of the front caliper first, then bleed the inside piston.
5. Repeat the procedure for each caliper until no air bubbles are in the fluid. Bleed the calipers in the sequence shown. Front - A/T model Front - M/T model Rear
6. Refill the master cylinder reservoir to the MAX (upper) level line (A).
7. Test-drive the vehicle and make at least two slow ABS activating stops.
8. Check for pedal feel. If the pedal feel is hard, you are done. If the pedal feel is soft, repeat the brake system bleeding procedure.

Scheme 17

Scheme 18

1. Remove the center console rear section (see «CENTER CONSOLE REAR SECTION REMOVAL/INSTALLATION»(/acura/tl/iii-2003-2006/remont/gauges-instrument-panels/#consoles__center-console-rear-section-removalinstallation) ).
2. Disconnect the connector (A) from the parking brake switch (B).
3. Check for continuity between the positive terminal (C) and body ground. With the parking brake lever pulled, there should be continuity. With the parking brake lever released, there should be no continuity. NOTE: If both the ABS/VSA indicator and the brake system indicator come on at the same time, check the VSA first. If the parking brake switch/fluid level switch is OK, but the brake system indicator does not function, check the VSA.

Brake Fluid Level Switch Test

Check for continuity between the terminals (1) with the float in the down position and in the up position.

Scheme 19

1. Remove the brake fluid completely from the reservoir. With the float down, there should be continuity.
2. Fill the reservoir with brake fluid to the MAX (upper) level (A). With the float up, there should be no continuity.

Front Brake Pad Inspection and Replacement

Special Tools Required

Brake caliper piston compressor 07AAE-SEPA101

Inspection

Note. Due to the high performance nature of the brake system on M/T model, the rotors and pads may wear faster than on A/T model. Be sure to inspect the front rotor thickness anytime the front pads are replaced.

Scheme 20

Scheme 21

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the front wheels. Take care not to scratch the calipers (M/T model).
3. Remove the brake pads.
4. Check the thickness of the brake pads (A). Do not include the thickness of the brake pad backing plate (B). Brake pad thickness: Standard: A/T model: 10.3-11.0 mm (0.41-0.43 in.) M/T model (4-piston caliper type): 8.8-10.0 mm (0.35-0.39 in.) Service limit: 1.6 mm (0.06 in.) A/T model M/T model (4-piston caliper type)
5. If the brake pad thickness is less than the service limit, replace all the brake pads as a set.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the front wheels.
3. Remove the brake hose mounting bolts (A).
4. Remove the flange bolt (B) while holding the pin (C) with a wrench being careful not to damage the pin boot, and pivot the caliper (D) up out of the way. Check the hose and pin boots for damage and deterioration.
5. Remove the pad shims (A) and the brake pads (B).
6. Remove the pad retainers (A).
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Clean and install the pad retainers.
10. Apply Molykote M-77 assembly paste (P/N 08798-9010) to the brake pad side of inner pad shim (A), inner pad shim (B), both sides of the outer pad shim (C), outer pad shim (D) the back of the brake pads (E), and to the other areas indicated by the arrows. Wipe excess assembly paste off the shims and the brake pads. Contaminated brake discs or pads reduce stopping ability. Keep grease and assembly paste off the brake discs and pads.
11. Install the brake pads and pad shims correctly. Install the brake pad with the wear indicator (F) on the upper-inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
12. Push in the piston (B) so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down.
13. Pivot the caliper (C) down into position. Install the flange bolt (D), and torque it to the specified torque while holding the pin (A) with a wrench being careful not to damage the pin boot.
14. Install the brake hose mounting bolts, and tighten them to the specified torque.
15. Press the brake pedal several times to make sure the brakes work, then test-drive the vehicle. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.
16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
17. Reinstall the front wheels.

Replacement: M/T model (4-piston caliper type)

Note. Due to the high performance nature of the brake system on M/T model, the rotors and pads may wear faster than on A/T model. Be sure to inspect the front rotor thickness anytime the front pads are replaced.

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the front wheels. Take care not to scratch the calipers.
3. Depress pad spring (A). Remove pad pins (B) from caliper by pushing from the outside to the inside with a commercially available 5/32" pin punch (C).
4. Remove the brake pads (A).
5. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
6. Check the brake disc for damage and cracks.
7. Mount the special tool (A) on the caliper.
8. Press in the outside and inside pistons with the brake caliper wrench so the caliper will fit over the pads.
9. Remove the special tool
10. Apply Molykote CU-7439 PLUS PASTE to the back of the brake pads (A). Wipe excess grease off the pads. Contaminated brake discs or brake pads reduce stopping ability. Keep grease off the brake disc and pads.
11. Install the brake pads correctly. Install the brake pad with the wear indicator (B) on the outside bottom. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
12. Install the pad spring (A).
13. Hold the pad spring, and install the pad pins (B) into the caliper from the inside to the outside of vehicle using the special tool.
14. Reinstall the front wheels. Take care not to scratch the calipers.
15. Press the brake pedal several times to make sure the brakes work. NOTE: Engagement of the brakes may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.
16. After installation, check for leaks at the brake hose and line joints or connections, and retighten if necessary, then test-drive.

Scheme 32

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the front wheels. Take care not to scratch the calipers (M/T model).
3. Remove the brake pads: A/T model (see «REPLACEMENT: A/T MODEL»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ), M/T model (see «REPLACEMENT: M/T MODEL (4-PISTON CALIPER TYPE)»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__replacement-mt-model-4-piston-caliper-type) ).
4. Inspect the brake disc surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust.
5. Install suitable flat washers (A) and wheel nuts (B), and tighten the nuts to the specified torque to hold the brake disc securely against the hub.
6. Set up the dial gauge (C) against the brake disc as shown, and measure the runout at 10 mm (3/8 in.) from the outer edge of the brake disc. Brake disc runout: Service limit: 0.10 mm (0.004 in.)
7. If the brake disc is beyond the service limit, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. Max refinishing limit: A/T model: 26.0 mm (1.02 in.) M/T model (4-piston caliper type): 23.0 mm (0.91 in.) NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see «KNUCKLE/HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ). A new brake disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

Scheme 33

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the front wheels. Take care not to scratch the calipers (M/T model).
3. Remove the brake pads: A/T model (see «REPLACEMENT: A/T MODEL»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ), M/T model (see «REPLACEMENT: M/T MODEL (4-PISTON CALIPER TYPE)»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__replacement-mt-model-4-piston-caliper-type) ).
4. Using a micrometer, measure brake disc thickness at eight points, approximately 45° apart and 10 mm (3/8 in.) in from the outer edge of the brake disc. Replace the brake disc if the smallest measurement is less than the max. refinishing limit. Brake disc thickness: A/T model: Standard: 27.9-28.1 mm (1.10-1.11 in.) Max. refinishing limit: 26.0 mm (1.02 in.) M/T model (4-piston caliper type): Standard: 24.9-25.1 mm (0.98-0.99 in.) Max. refinishing limit: 23.0 mm (0.91 in.) Brake disc parallelism: 0.015 mm (0.0006 in.) max. NOTE: Parallelism is the maximum allowable difference between the thickness measurements.
5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. NOTE: If the brake disc is beyond the service limit for refinishing limit, replace the it (see «KNUCKLE/HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-front/#front-suspension) ).

Front Brake Caliper Overhaul

Remove, disassemble, inspect, reassemble, and install the caliper, and note these items

Note. Make sure that the caliper pins are installed correctly.

The top and bottom caliper pins are different. If the top and bottom caliper pins are installed in the wrong location, it will cause uneven tire wear, vibration, and or uneven or rapid pad wear.

1. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
2. To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
3. Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
4. Before reassembling, check that all parts are free of dirt and other foreign particles.
5. Replace parts with new ones as specified in the illustration.
6. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
7. Make sure no grease or oil gets on the brake discs or pads.
8. When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
9. Do not reuse drained brake fluid. Use only clean ACURA DOT 3 brake fluid from an unopened container. Using a non-Acura brake fluid can cause corrosion and shorten the life of the system.
10. Do not mix different brands of brake fluid as they may not be compatible.
11. Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
12. Replace all rubber parts with new ones whenever disassembled.
13. After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

Scheme 34

M/T model (4-piston caliper type)

Note. Do not disassemble these calipers, they can not be rebuilt.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Lower the vehicle on the ground.
2. Remove the covers (A) in the engine compartment.
3. Remove the under-hood fuse/relay box (A), and move it aside.
4. Remove the engine wire harness clamp (A) from the strut brace.
5. Remove the accelerator pedal position (APP) sensor mounting bolt (A) from the strut brace.
6. With the vehicle on the ground, remove the strut brace (A).
7. Remove the reservoir cap and brake fluid from the master cylinder reservoir.
8. Disconnect the brake fluid level switch connector (A).
9. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels. NOTE: 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.
10. Remove the master cylinder mounting nuts (D) and washers.
11. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder.
12. Remove the rod seal (F) from the master cylinder.
13. Install the master cylinder in the reverse order of removal, and note these items: Replace all the rubber parts with new ones whenever the master cylinder is removed. Use a new rod seal on reassembly. Coat the inner bore lip and outer circumference of the new rod seal with the recommended seal grease. Install the rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary.
14. Bleed the brake system (see «BRAKE SYSTEM BLEEDING»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__brake-system-bleeding) ).
15. Spin the wheels to check for brake drag.

Master Cylinder Inspection

Note. Before reassembling, check that all parts are free of dirt and other foreign particles. Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. Do not allow dirt or foreign matter to contaminate the brake fluid.

Functional Test

1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the brake pedal hard, and hold it for 15 seconds. If the brake pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, or caliper) is leaking.
2. Start the engine with the brake pedal pressed. If the pedal sinks slightly, the vacuum booster is operating normally. If the brake pedal height does not vary, the booster or check valve is faulty.
3. With the engine running, press the brake pedal lightly and shift the transmission to the D position. Apply just enough pressure to hold back automatic transmission creep. If the brake pedal sinks more than 10 mm (3/8 in.) in 3 minutes, the master cylinder is faulty. A slight change in brake pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the booster.)

Scheme 42

1. Press the brake pedal with the engine running, then stop the engine. If the brake pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal height rises go to step 6. If it does not rise go to step 2.
2. Start the engine and let it idle for 30 seconds. Turn the engine off, and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. Does the pedal rise on each consecutive application? If it rises the booster is OK. If it does not go to step 3.
3. Disconnect the brake booster vacuum hose (A) at the booster. The check valve (B) is built into the hose.
4. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. If vacuum is found, go to step 5.
5. Reconnect the vacuum hose to the brake booster.
6. Start the engine, and then pinch the brake booster vacuum hose between the check valve and the booster.
7. Turn the engine off and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary inspect the seal between the master cylinder and booster. If the seal is OK, replace the brake booster. If the pedal position varies, replace the brake booster vacuum hose/check valve assembly

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Remove the master cylinder (see «MASTER CYLINDER REPLACEMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ).
2. Disconnect the vacuum hose (A) from the brake booster (B).
3. Remove the air cleaner assembly (A).
4. Remove the primary and secondary brake lines (A) from the hose clamp (B).
5. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke (C) from the brake pedal.
6. Remove the brake booster mounting nuts (D).
7. Remove the brake booster (A) from the engine compartment. NOTE: Be careful not to damage the booster surfaces and threads of the booster stud bolts. Be careful not to bend or damage the brake lines.
8. Install the brake booster in the reverse order of removal, and note these items: Use a new lock pin whenever installing. After installing the brake booster and master cylinder, fill the reservoir with new brake fluid from an unopened container bleed the brake system (see «BRAKE SYSTEM BLEEDING»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__brake-system-bleeding) ), and adjust the brake pedal height and free play (see «BRAKE PEDAL AND BRAKE PEDAL POSITION SWITCH ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ).

Rear Brake Pad Inspection and Replacement

Scheme 48

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Check the thickness of the inner brake pad (A) and outer pad (B). Do not include the thickness of the backing plate.
4. If the brake pad thickness is less than the service limit, replace all the rear brake pads as a set.

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Release the parking brake.
4. Remove the brake hose (A) from the bracket by removing the mounting bolt.
5. Remove the caliper bolts (B) while holding the caliper pins (C) with a wrench being careful not to damage the pin boot, and remove the caliper (D). Check the hose and pin boots for damage and deterioration. Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside. Support the caliper with a piece of wire so it does not hang from the brake hose.
6. Remove the pad shims (A) and brake pads (B).
7. Remove the pad retainers (A).
8. Clean the caliper thoroughly; remove any rust and check for grooves and cracks.
9. Check the brake disc/drum for damage and cracks.
10. Install the pad retainers.
11. Apply Molykote M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), and back of the brake pads (B) and the other areas indicated by the arrows. Wipe excess assembly paste off the pad shims and brake pads. Contaminated brake discs or pads reduce stopping ability. Keep grease and assembly paste off the discs and pads.
12. Install the brake pads and pad shims on the caliper bracket. Install the inner brake pad with its wear indicator (C) facing downward. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency.
13. Push in the piston so the caliper will fit over the brake pads. Make sure the piston boot is in position to prevent damaging it when installing the caliper.
14. Install the brake caliper (A).
15. Install the caliper bolts (B), and torque it to the specified torque while holding the caliper pin (C) with a wrench being careful not to damage the pin boot.
16. Install the brake hose (D) onto the bracket with the mounting bolt.
17. Press the brake pedal several times to make sure the brakes work. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.
18. After installation, check for leaks at the hose and line joints and connections, and retighten if necessary.

Scheme 54

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Remove the brake pads (see «REAR BRAKE PAD INSPECTION AND REPLACEMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__rear-brake-pad-inspection-and-replacement) ).
4. Inspect the brake disc/drum surface for damage and cracks. Clean the brake disc/drum thoroughly, and remove all rust.
5. Install suitable flat washers (A) and wheel nuts (B), and tighten the wheel nuts to the specified torque to hold the brake disc/drum securely against the hub.
6. Set up the dial gauge (C) against the brake disc/drum as shown, and measure the runout at 10 mm (3/8 in.) from the outer edge of the brake disc. Brake disc/drum runout: Service limit: 0.10 mm (0.004 in.)
7. If the brake disc/drum is beyond the service limit, refinish the brake disc/drum with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. Max. refinishing limit: 7.5 mm (0.30 in.) NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see «HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-rear/#rear-suspension) ). A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

Scheme 55

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Remove the brake pads (see «REAR BRAKE PAD INSPECTION AND REPLACEMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__rear-brake-pad-inspection-and-replacement) ).
4. Using a micrometer (A), measure disc thickness at eight points, about 45° apart and 10 mm (3/8 in.) in from the outer edge of the brake disc/drum. Replace the brake disc if the smallest measurement is less than the max. refinishing limit. Brake disc/drum thickness: Standard: 8.9-9.1 mm (0.350-0.358 in.) Max. refinishing limit: 7.5 mm (0.30 in.) Brake disc/drum parallelism: 0.015 mm (0.0006 in.) max. NOTE: Parallelism is the maximum allowable difference between the thickness measurements.
5. If the brake disc/drum is beyond the service limit for parallelism, refinish the brake disc/drum with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see «HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-rear/#rear-suspension) ).

Rear Brake Caliper Overhaul

Remove, disassemble, inspect, reassemble, and install the caliper, and note these items

Scheme 56

1. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water.
2. To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
3. Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
4. Before reassembling, check that all parts are free of dirt and other foreign particles.
5. Replace parts with new ones as specified in the illustration.
6. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
7. Make sure no grease or oil gets on the brake discs or pads.
8. When reusing brake pads, always reinstall them in their original positions to prevent loss of braking efficiency.
9. Do not reuse drained brake fluid. Use only clean ACURA DOT 3 Brake Fluid from an unopened container. Using a non-Acura brake fluid can cause corrosion and shorten the life of the system.
10. Do not mix different brands of brake fluid as they may not be compatible.
11. Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
12. Replace all rubber parts with new ones whenever disassembled.
13. After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

Parking Brake Inspection

Scheme 57

Scheme 58

Scheme 59

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Release the parking brake, and remove the rear brake caliper and brake disc/drum (see «HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-rear/#rear-suspension) ).
4. Check the parking brake linings (A) for cracking, glazing, wear, and contamination.
5. Measure the parking brake lining thickness (B). Measurement does not include brake shoe thickness. Parking brake lining thickness: Standard: 3.2 mm (0.126 in.) Service limit: 1.0 mm (0.04 in.)
6. If the parking brake lining thickness is less than the service limit, replace all the parking brake shoes as a set.
7. Check the bearings in the hub unit for smooth operation.
8. Measure the inside diameter of the parking brake drum with inside vernier calipers. Parking brake drum inside diameter: Standard: 169.9- 170.0 mm (6.689 - 6.693 in.) Service limit: 171.0 mm (6.732 in.)
9. If the inside diameter of the parking brake disc/ drum is more than service limit, replace the brake disc/drum.
10. Check the parking brake drum for scoring, grooves, and cracks.

Parking Brake Shoe Replacement

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-219517-S06925466662006021400000) ).
2. Remove the rear wheels.
3. Release the parking brake and remove the rear brake caliper and brake disc/drum (see «HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-rear/#rear-suspension) ).
4. Disconnect and remove the upper return springs (A).
5. Remove the tension pins (A) by pushing the retainer springs (B) and turning the pins.
6. Disconnect the rod spring (A), and remove the connecting rod (B).
7. Lower the parking brake shoe assembly.
8. Remove the forward brake shoe by removing the lower return spring (A) and adjuster assembly (B).
9. Remove the rearward brake shoe by disconnecting the parking brake cable (A) from the parking brake lever (B).
10. Remove the U-clip (A), wave washer (B), parking brake lever (C), and pivot pin (D) from the brake shoe.

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Apply Molykote 44 MA grease to the sliding surface of the pivot pin (A), and insert the pin into the brake shoe (B) from the rear side.
2. Install the parking brake lever (C) and wave washer (D) on the pivot pin, and secure with a new U-clip (E). Install the wave washer with its convex side facing out. Pinch the U-clip securely to prevent the pivot pin from coming out from the brake shoe.
3. Connect the parking brake cable (A) to the parking brake lever (B). Apply silicone grease to the cable contact surface (C) on the backing plate.
4. Apply Molykote 44 MA grease to the shoe ends and connecting rod ends (A), sliding surfaces (B), and opposite edges of the parking brake shoe (C) as shown. Wipe off any excess. Keep grease off the brake linings.
5. Clean the threaded portions of the clevis A, and coat the threads of the clevis with grease. Clean the sliding surface of the clevis B, and coat the sliding surface of the clevis B with grease. Install the clevis A and B on the adjuster (C) and shorten the clevis A by turning the adjuster.
6. Reinstall the brake shoe adjuster assembly (D), and hook the lower return spring (E) on the parking brake shoes.
7. Hook the rod spring (A) or the connecting rod (B) first with the spring end (C) pointing downward. Then hook the rod spring to the parking brake shoe, and install the connecting rod on the parking brake shoes.
8. Reinstall the tension pins (A) and retainer springs (B). Make sure the tension pin does not contact to the parking brake lever.
9. Reinstall the upper return springs (A).
10. Install the rear brake disc/drum and rear brake caliper (see «HUB REPLACEMENT»(/acura/tl/iii-2003-2006/remont/suspension-rear/#rear-suspension) ).
11. Do the major parking brake adjustment (see «MINOR ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ).

Parking Brake Shoe Lining Break-in

Note. Do the brake lining surface break-in when replacing shoes and/or the rear brake disc/drum.

Scheme 73

1. Park the vehicle on a firm, level surface.
2. Do the major parking brake adjustment (see «MINOR ADJUSTMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ).
3. Keep the parking brake lever release button pushed with a piece of tape (A).
4. Drive the vehicle at 25 mph (40 km/h).
5. Pull the parking brake lever up with 98 N.m (10 kgf, 22 lbf) of force while you are driving the vehicle for 400 m (1/4 mile).
6. Pull the parking brake lever up with 147 N.m (15 kgf, 33 lbf) of force while you are driving the vehicle for 10 seconds.
7. Stop the vehicle and release the parking brake lever for 5-10 minutes to allow the rear brake disc/drum to cool.
8. Check the parking brake lever adjustment (see «PEDAL FREE PLAY»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ).

Scheme 74

1. Remove the lock pin (A) and joint pin (B).

Scheme 75

1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting.
2. Check the brake lines for damage, rusting, and leaks. Also check for bent brake lines.
3. Check for leaks at hose and line joints and connections, and retighten if necessary.
4. Check the master cylinder and VSA modulator-control unit for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced. BRAKE HOSE AND LINE INSPECTION TABLE Connection Point Component Connected to Specified Torque Value Note A Front brake caliper (A/T model) Brake hose 34 N.m (3.5 kgf.m, 25 lbf.ft) Banjo bolt Breed screw 9 N.m (0.9 kgf.m, 7 lbf.ft) Front brake caliper (M/T model: 4-piston caliper type) Brake line 15 N.m (1.5 kgf.m, 11 lbf.ft) Banjo bolt Breed screw 20 N.m (2.0 kgf.m, 14 lbf.ft) B Rear brake caliper Brake hose 34 N.m (3.5 kgf.m, 25 lbf.ft) Banjo bolt Breed screw 9 N.m (0.9 kgf.m, 7 lbf.ft) C Brake hose Brake line 15 N.m (1.5 kgf.m, 11 lbf.ft) Flare nut D Master cylinder Brake line (14 mm nut) 29 N.m (3.0 kgf.m, 22 lbf.ft) Flare nut ('04 model) Brake line (12 mm nut) 22 N.m (2.2 kgf.m, 16 lbf.ft) Flare nut ('05-06 models) E VSA modulator-control unit Brake line (14 mm nut) 29 N.m (3.0 kgf.m, 22 lbf.ft) Flare nut ('04 model) Brake line (12 mm nut) 22 N.m (2.2 kgf.m, 16 lbf.ft) Flare nut ('05-06 models) Brake line (10 mm nut) 15 N.m (1.5 kgf.m, 11 lbf.ft) Flare nut F 4-way joint Brake line 15 N.m (1.5 kgf.m, 11 lbf.ft) Flare nut

Brake Hose Replacement

Note. Before reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones whenever specified to do so. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. To prevent dripping, cover disconnected line joints with rags or shop towels.

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Replace the brake hose (A) if the hose is twisted, cracked, or leaking.
2. Disconnect the brake hose from the brake line (B) using a 10 mm flare-nut wrench (C).
3. Remove and discard the brake hose clip (A) from the brake hose (B).
4. Remove the banjo bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.
6. Install the brake hose (A) on the damper with flange bolts (B) first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).
7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
8. Connect the brake line (D) to the brake hose.
9. After installing the brake hose, bleed the brake system (see «BRAKE SYSTEM BLEEDING»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__brake-system-bleeding) ).
10. Do the following checks: Check the brake hose and line joint for leaks, and tighten if necessary. Check the brake hoses for interference and twisting.

Scheme 80

Note. The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. Refer to the Exploded View as needed during this procedure.

Scheme 81

1. Remove the parking brake shoes, and disconnect the parking brake cable from the brake shoe (see «PARKING BRAKE SHOE REPLACEMENT»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components__parking-brake-shoe-replacement) ).
2. Remove the parking brake cable mounting bolts from the backing plate (A), and remove the parking brake cable (B).
3. Install the parking brake cable in the reverse order of removal, and adjust the parking brake (see «PEDAL FREE PLAY»(/acura/tl/iii-2003-2006/remont/mechanical-hydraulic/#conventional-brake-components) ). Apply the parking brake firmly 10 times, then adjust it again.

See also:
• CENTER CONSOLE REAR SECTION REMOVAL/INSTALLATION
• KNUCKLE/HUB REPLACEMENT
• HUB REPLACEMENT
• FRONT BRAKE CALIPER OVERHAUL
• PARKING BRAKE SHOE LINING BREAK-IN
• REPLACEMENT: A/T MODEL
• REPLACEMENT: M/T MODEL (4-PISTON CALIPER TYPE)
• BRAKE SYSTEM BLEEDING
• REAR BRAKE PAD INSPECTION AND REPLACEMENT
• PARKING BRAKE SHOE REPLACEMENT