Disc: Removal & Installation Honda Pilot I

REMOVAL & INSTALLATION

1. Remove the lock pin and joint pin.
2. Remove the brake pedal bracket mounting bolt and nuts.
3. Disconnect the brake pedal position switch connector.
4. Remove the brake pedal with bracket.
5. Install in the reverse order of removal. Replace the lock pin whenever the brake pedal is replaced.
6. Do the brake pedal and brake pedal position switch adjustment. See «ADJUSTMENTS»(ref-164864-S16077085922004081700000) .

Note. An on-car brake lathe must be used to resurface front brake disc.

1. Raise and support vehicle. Remove wheels. Remove caliper assembly, and suspend it using wire. Install washers and nuts to hold rotor to hub. Attach dial indicator to caliper mount .40" (10.0 mm) from disc outer edge. Check disc runout before removal. See «FRONT BRAKE DISC»(ref-164864-S33999493112004081700000) under TESTING & INSPECTION. See appropriate table under «DISC BRAKE SPECIFICATIONS»(ref-164864-S35112101622004081700000) .
2. Detach and remove two 6-mm disc retaining screws. Install two 8 x 1.25 x 12-mm bolts in existing holes. To prevent warpage, alternately turn bolts 2 turns at a time until disc can be removed from hub.
3. Clean disc of all rust, and inspect disc surfaces for cracks and grooves. Replace disc as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system, if necessary. See «BLEEDING BRAKE SYSTEM»(ref-164864-S34529760282004081700000) .

Note. Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary.

Remove the intake air dust. Disconnect brake fluid level switch connector and remove the reservoir cap. Remove brake fluid from reservoir. Disconnect brake lines from master cylinder. Use shop towels to prevent spillage. Remove master cylinder mounting nuts. Remove master cylinder from brake booster. Be careful not to damage brake lines when removing. Install in reverse order of removal. Bleed hydraulic system. See BLEEDING BRAKE SYSTEM .

Scheme 9

Remove master cylinder. See MASTER CYLINDER. Remove air intake duct. Remove cable bracket from throttle body, then disconnect throttle cable end and cruise control actuator cable end from throttle linkage. (Scheme 10) Disconnect vacuum hose from brake booster. Remove lock pin and joint pin from brake pedal. Remove 4 booster mounting nuts. (Scheme 11) Pull booster forward, and remove it from engine compartment. Install in reverse order of removal. Tighten mounting nuts to specification. See TORQUE SPECIFICATIONS. Adjust brake pedal height and free play. See ADJUSTMENTS. Adjust throttle cable and cruise control actuator cable, if necessary. For throttle cable, see THROTTLE under ADJUSTMENTS. For cruise control actuator cable, see appropriate CRUISE CONTROL SYSTEMS article in ACCESSORIES & EQUIPMENT.

Scheme 10

Scheme 11

Note. The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.

1. Remove the parking brake shoes. See «PARKING BRAKE SHOES»(ref-164864-S35050269072004081700000). Disconnect the parking brake cable from the brake shoe. (Scheme 12)
2. Remove the parking brake cable from the backing plate using a 12-mm offset wrench to collapse locking tabs.
3. Install the parking brake cable in the reverse order of removal. Adjust the parking brake. See «PARKING BRAKE»(ref-164864-S12498554022004081700000) under ADJUSTMENTS. Apply the parking brake firmly 10 times, then adjust it again.

Scheme 12

Removal

1. Raise and support vehicle. Remove rear wheels. Release parking brake, and remove rear brake caliper and brake disc/drum. See «BRAKE DISC (FRONT & REAR)»(ref-164864-S06657858992004081700000) . Disconnect and remove upper return springs. Remove tension pins by pushing retainer springs and turning pins/retainers. Disconnect rod springs, and remove connecting rod.
2. Lower parking brake shoe assembly. Remove forward brake shoe by removing lower return spring and adjuster assembly. Remove rearward brake shoe by disconnecting parking brake cable from parking brake lever. Remove U-clip, wave washer, parking brake lever, and pivot pin from brake shoe.

Installation

1. Apply Molykote 44 MA grease to sliding surface of pivot pin, and insert pin into rearward brake shoe. Install parking brake lever and wave washer on pivot pin, and secure with a NEW U-clip. Install wave washer with its convex side facing out. Pinch U-clip securely to prevent pivot pin from coming out from brake shoe.
2. Connect parking brake cable to parking brake lever. Apply Molykote 44 MA grease to shoe ends, sliding surfaces, and opposite edges of parking brake shoe. Install tension pin, retainer spring, and retainer of rearward brake shoe. Make sure tension pin does not contact parking brake lever. Clean threaded portions of clevis A, and coat threads of clevis with grease. Clean sliding surface of clevis B, and coat sliding surface of clevis B with grease. Install clevis A and B on adjuster, and shorten clevis by turning adjuster.
3. Reinstall brake shoe adjuster assembly, and hook lower return spring on parking brake shoes. Then hook rod spring to parking brake shoe, and install connecting rod on parking brake shoes. Reinstall tension pins and retainer springs. Make sure tension pin does not contact parking brake lever. Reinstall upper return springs. Install rear brake disc/drum and rear brake caliper. Perform parking brake shoe lining break-in. See «PARKING BRAKE SHOE LINING BREAK-IN»(ref-164864-S31011680882004081700000) .