Conventional Brake Components: Component Locations Honda Pilot II

Special Tools Required

Brake Caliper Piston Compressor 07AAE-SEPA101

Scheme 39

Scheme 40

1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the front wheels.
3. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. Brake pad thickness: Standard: 10.6-11.2 mm (0.417-0.441 in) Service limit: 1.6 mm (0.063 in) Inner pad Outer pad
4. If any of the brake pad thickness is less than the service limit, replace the front brake pads as a set.
5. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheels.

Scheme 41

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Scheme 48

1. Remove some brake fluid from the master cylinder.
2. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
3. Remove the front wheels.
4. Remove the flange bolt (A), and pivot the caliper (B) up out of the way. Check the hose and pin boots for damage and deterioration.
5. Remove the pad springs (A) while holding the brake pads.
6. Remove the pad shims (A) and the brake pads (B).
7. Remove the pad retainers (A). NOTE: The upper and lower pad retainers are different. During installation, make sure the pad retainers are in proper positions.
8. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed.
9. Inspect the brake disc, for runout, thickness, parallelism (see «FRONT BRAKE DISC INSPECTION»(ref-333576-S36323738182009072100000) ) and check for damage and cracks
10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows).
11. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off the brake disc and the brake pads.
12. Install the brake caliper piston compressor tool (A) on the caliper body (B).
13. Press in the piston with the brake caliper piston compressor tool 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. NOTE: Be careful when pressing in the piston; brake fluid might overflow from the master cylinder's reservoir. If brake fluid gets on any painted surface, wash it off immediately with water.
14. Remove the brake caliper piston compressor tool.
15. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the back of the brake pads (B) and the other areas indicated by the arrows. Wipe excess assembly paste off the pad shims and the brake pads friction material. Keep grease and assembly paste off the brake disc and brake pads. Contaminated brake disc or brake pads reduce stopping ability.
16. Install the brake pads and the pad shims correctly. Install the brake pad with the wear indicator (C) 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.
17. Install the pad springs (A) while holding the brake pads.
18. Pivot the caliper down into position, while holding the brake pads. Install the flange bolt (A), and tighten it to the specified torque.
19. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheels.
20. Press the brake pedal several times to make sure the brakes work. NOTE: Engagement 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.
21. Add brake fluid as needed.
22. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then recheck for leaks (see «BRAKE HOSE AND LINE INSPECTION»(ref-333576-S17847355052009072100000) ).

Scheme 49

1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the front wheels.
3. Remove the brake pads (see «REPLACEMENT»(ref-333576-S37620277082009072100000) ).
4. Inspect the brake disc to wheel 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 wheel nuts to the specified torque to hold the brake disc securely against the hub.
6. Set up the dial gauge against the brake disc as shown below, and measure the runout at 10 mm (0.39 in.) from the outer edge of the brake disc. Brake disc runout: Service limit: 0.04 mm (0.0016 in)
7. If the brake disc is beyond the service limit, refinish the brake disc with an American - Honda - approved commercially available on-car brake lathe. Max. refinishing limit: 26.0 mm (1.024 in) NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see «FRONT BRAKE DISC REPLACEMENT»(ref-333576-S23336591842009072100000) ). If the brake disc is replaced with a new one, check the new disc for runout. If the new disc is out of specification, refinish the disc.
8. Install the brake pads (see «REPLACEMENT»(ref-333576-S37620277082009072100000) ).
9. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheels.

Scheme 50

1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the front wheels.
3. Remove the brake pads (see «REPLACEMENT»(ref-333576-S37620277082009072100000) ).
4. Using a micrometer, measure the brake disc thickness at eight points, about 45° apart and 10 mm (.39 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: Standard: 27.9-28.1 mm (1.098-1.106 in) Max. refinishing limit: 26.0 mm (1.024 in) Brake disc parallelism: 0.015 mm (0.00059 in) max. NOTE: This 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 American - Honda - approved commercially available on-car brake lathe. NOTE: If the brake disc is beyond the service limit for refinishing, replace it (see «FRONT BRAKE DISC REPLACEMENT»(ref-333576-S23336591842009072100000) ).
6. Install the brake pads (see «REPLACEMENT»(ref-333576-S37620277082009072100000) ).
7. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheels.

Brake Caliper Piston Compressor 07AAE-SEPA101

Scheme 51

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the rear wheels.
3. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. Brake pad thickness: Standard: 9.6-10.2 mm (0.378-0.402 in) Service limit: 1.6 mm (0.063 in)
4. If any of the brake pad thickness is less than the service limit, replace the rear brake pads as a set.
5. Clean the mating surfaces between the brake disc/drum and the inside of the wheel, then install the rear wheels.

Scheme 52

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Scheme 56

Scheme 57

1. Remove some brake fluid from the master cylinder.
2. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
3. Remove the rear wheels.
4. Remove the flange bolt (A), and pivot the caliper (B) 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 upper and lower pad retainers (A). NOTE: The upper and lower pad retainers are different. During installation, make sure the pad retainers are in their proper positions.
7. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed.
8. Inspect the brake disc/drum for runout, thickness, parallelism, and check for damage and cracks (see «REAR BRAKE DISC INSPECTION»(ref-333576-S06581046822009072100000) ).
9. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows and shaded area).
10. Install the upper and lower pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off the discs/drum and brake pads.
11. Install the brake caliper piston compressor tool (A) on the caliper body (B).
12. Press in the piston with the brake caliper piston compressor tool 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. NOTE: Be careful when pressing in the piston; brake fluid might overflow from the master cylinder's reservoir. If brake fluid gets on any painted surface, wash it off immediately with water.
13. Remove the brake caliper piston compressor tool.
14. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the 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 friction material. Keep grease and assembly paste off the brake disc/drum and brake pads. Contaminated brake disc/drum or brake pads reduce stopping ability.
15. Install the brake pads and pad shims correctly. Install the brake pad with the wear indicator (C) on the bottom 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.
16. Pivot the caliper down into position. Install the flange bolt (A), and tighten it to the specified torque.
17. Clean the mating surfaces between the brake disc/drum and the inside of the wheel, then install the rear wheels.
18. Press the brake pedal several times to make sure the brakes work. NOTE: Engagement 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.
19. Add brake fluid as needed.
20. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then check for leaks (see «BRAKE HOSE AND LINE INSPECTION»(ref-333576-S17847355052009072100000) ).

Scheme 58

1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the rear wheels.
3. Remove the brake pads (see «REPLACEMENT»(ref-333576-S39771633372009072100000) ).
4. Inspect the brake disc/drum to wheel 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 against the brake disc/drum as shown below, and measure the runout at 10 mm (.39 in.) from the outer edge of the brake disc/drum. Brake disc/drum runout: Service limit: 0.04 mm (0.002 in)
7. If the brake disc/drum is beyond the service limit, refinish the brake disc/drum with an American - Honda - approved commercially available on-car brake lathe. Max. refinishing limit: 9.0 mm (0.354 in) NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see «REAR BRAKE DISC REPLACEMENT»(ref-333576-S26037553752009072100000) ). If the brake disc is replaced with a new one, check the new disc for runout. If the new disc is out of specification, refinish the disc.
8. Install the brake pads (see «REPLACEMENT»(ref-333576-S39771633372009072100000) ).
9. Clean the mating surfaces between the brake disc/drum and the inside of the wheel, then install the rear wheels.

Scheme 59

1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the rear wheels.
3. Remove the brake pads (see «REPLACEMENT»(ref-333576-S39771633372009072100000) ).
4. Using a micrometer, measure the brake disc/drum thickness at eight points, about 45° apart and 10 mm (.39 in.) in from the outer edge of the brake disc/drum. Replace the brake disc/drum if the smallest measurement is less than the max. refinishing limit. Brake disc/drum thickness: Standard: 10.9-11.1 mm (0.429-0.437 in) Max. refinishing limit: 9.0 mm (0.354 in) Brake disc/drum parallelism: 0.015 mm (0.00059 in) max NOTE: This 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 American - Honda - approved commercially available on-car brake lathe. NOTE: If the brake disc/drum is beyond the service limit for refinishing, replace it (see «REAR BRAKE DISC REPLACEMENT»(ref-333576-S26037553752009072100000) ).
6. Install the brake pads (see «REPLACEMENT»(ref-333576-S39771633372009072100000) ).
7. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear wheels.