Conventional Brake Components: Removal & Installation Honda Pilot II

Front Brake Disc Replacement

Note. Keep any grease off the brake disc and brake pads.

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1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the front wheel.
3. Remove the brake hose mounting bolt (A).
4. Remove the brake caliper bracket mounting bolts (B), then remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose excessively.
5. Remove the brake disc flathead screws (A).
6. Remove the brake disc (B) from the hub bearing unit. NOTE: If the brake disc is stuck to the hub bearing unit, thread two 8 x 1.25 mm bolts (C) into the brake disc to push it away from the hub bearing unit. Turn each bolt 90 degrees at a time to prevent the brake disc from binding.
7. Install the brake disc in the reverse order of removal. NOTE: Before installing the brake disc, clean the mating surfaces between the hub bearing unit and the inside of the brake disc.
8. Inspect the brake disc runout (see «FRONT BRAKE DISC INSPECTION»(ref-333576-S36323738182009072100000) ).
9. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheel.

Master Cylinder Replacement

Note. 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. Be careful not to damage or deform the brake lines during removal and installation. Plug the end of a hose and joints to prevent spilling brake fluid.

Scheme 12

1. Remove the reservoir cap and the brake fluid from the master cylinder reservoir with a syringe.
2. Disconnect the brake fluid level switch connector (A).
3. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with clean rags or shop towels.
4. Remove the master cylinder mounting nuts (D) and the washers (E).
5. Remove the master cylinder from the brake booster (F). Be careful not to bend or damage the brake lines when removing the master cylinder.
6. Remove the rod seal (G) from the master cylinder. NOTE: During installation, set the new rod seal onto the master cylinder with its grooved side (H) toward the master cylinder.
7. Install the master cylinder in the reverse order of removal, and note these items: Coat the inner bore lip and the outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798-9013). Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves. Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary (see «BRAKE PEDAL AND BRAKE PEDAL POSITION SWITCH ADJUSTMENT»(ref-333576-S40336238712009072100000) ).
8. Bleed the brake system (see «BRAKE SYSTEM BLEEDING»(ref-333576-S37338356352009072100000) ).
9. Spin the wheels to check for brake drag.

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1. Remove the master cylinder (see «MASTER CYLINDER REPLACEMENT»(ref-333576-S23484276092009072100000) ).
2. Inspect and note these items: 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.
3. Install the master cylinder (see «MASTER CYLINDER REPLACEMENT»(ref-333576-S23484276092009072100000) ).

Rear Brake Disc Replacement

Note. Keep any grease off the brake disc/drum and brake pads.

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1. Raise and support vehicle it with safety stands in the proper locations (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the rear wheel.
3. Release the parking brake pedal fully.
4. Remove the brake caliper bracket mounting bolts (A), and remove the caliper assembly (B) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose excessively. NOTE: Make sure the plates (C) are in position on reassembly, if they are removed (see «KNUCKLE/HUB BEARING UNIT REPLACEMENT»(ref-333574-S32737247552009072100000) ).
5. Remove the brake disc/drum flathead screws (A).
6. Remove the brake disc/drum (B) from the hub bearing unit. NOTE: Remove the access plug (C), then if necessary, turn the adjuster nut (D) with a flat-tip screwdriver until the shoes become loose. If the brake disc/drum is stuck to the hub bearing unit, thread two 8 x 1.25 mm bolts (E) into the brake disc/drum to push it away from the hub bearing unit. Turn each bolt 90 degrees at a time to prevent the brake disc/drum from binding.
7. Install the brake disc/drum in the reverse order of removal, and note these items: Before installing the brake disc/drum, clean the mating surfaces between the hub bearing unit and the inside of the brake disc/drum. Adjust the parking brake (see «PARKING BRAKE INSPECTION AND ADJUSTMENT»(ref-333576-S42479768412009072100000) ).
8. Inspect the brake disc runout (see «REAR BRAKE DISC INSPECTION»(ref-333576-S06581046822009072100000) ), and the thickness and parallelism (see «Thickness and Parallelism»(ref-333576-S28147383412009072100000) .
9. Clean the mating surfaces between the brake disc/drum and the inside of the wheel, then install the rear wheel.

Parking Brake Shoe Replacement

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1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the rear wheels.
3. Release the parking brake disc/drum and remove the brake disc/drum (see «REAR BRAKE DISC REPLACEMENT»(ref-333576-S26037553752009072100000) ).
4. Disconnect and remove the upper return springs (A), then remove the shoe guide plate (B).
5. Remove the tension pins (A) by pushing the respective retainer (B), and turning the pin.
6. Remove the strut (A) and the rod spring (B).
7. Lower the parking brake shoe assembly.
8. Remove the forward brake shoe (A) and the adjuster assembly (B) by removing the lower return spring (C).
9. Remove the rearward brake shoe (A) by disconnecting the parking brake cable (B) from the parking brake lever (C).
10. Remove the U-clip (A), wave washer (B), and parking brake lever (C) from the brake shoe (D).

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1. Apply Molykote 44MA to the sliding surface of the pivot pin (A) of the rearward brake shoe (B).
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 parking brake lever from coming off the brake shoe.
3. Connect the parking brake cable (A) to the parking brake lever (B). Apply Molykote 44MA to the cable contact surface (C) on the backing plate.
4. Apply a thin coat of Molykote 44MA to the shoe ends and strut ends (A), sliding surfaces (B), and opposite edges of the parking brake shoe (C) as shown. Wipe off any excess. Keep the grease off the brake linings.
5. Install the tension pin (A), the retainer spring (B), and the retainer (C) on the rearward brake shoe (D). Make sure the tension pin does not contact the parking brake lever.
6. Install connecting rods A and B on the adjuster nut (C). NOTE: Clean the threaded portions of connecting rod A and the sliding surface of connecting rod B, then coat them with rubber grease. Shorten connecting rod A by fully turning the adjuster nut.
7. Position the brake shoe adjuster assembly (D) on the parking brake shoes.
8. Hook the lower return spring (E) on the parking brake shoes.
9. Install the rod spring (A) to the strut (B) first. Then install the strut on the parking brake shoes.
10. Install the tension pin (A), the retainer spring (B), and the retainer (C) on the forward brake shoe (D).
11. Install the shoe guide plate (A).
12. Install the upper return springs (B) as shown below.
13. Install the brake disc/drum and the rear brake caliper (see «REAR BRAKE DISC REPLACEMENT»(ref-333576-S26037553752009072100000) ).
14. Do the major parking brake adjustment (see «MAJOR ADJUSTMENT (TO BE DONE WHEN REPLACING PARKING BRAKE SHOES AND AFTER LINING SURFACE BREAK-IN)»(ref-333576-S41301778332009072100000) ).
15. Clean the mating surfaces between the brake/drum and the inside of the wheel, then install the rear wheels.

Brake Hose Replacement

Note. 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. Before reassembling, check that all parts are free of dirt and other foreign particles. Replace parts with new ones whenever specified to do so. After removal, plug the end of a hose and joints to prevent spilling brake fluid.

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1. Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-333541-S31570824132009072100000) ).
2. Remove the front wheel.
3. Disconnect the brake line (A) from the brake hose (B), then remove the brake hose clip (C).
4. Remove the banjo bolt (A), and disconnect the brake hose (B) from the caliper.
5. Remove the brake hose mounting bolt (C), then remove the brake hose.
6. Install the brake hose (A) with the mounting bolt (B).
7. Connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D).
8. Install a new brake hose clip (A) to the brake hose (B) on the bracket, then connect the brake line (C). Do not twist the brake hose.
9. After installing the brake hose, bleed the brake system (see «BRAKE SYSTEM BLEEDING»(ref-333576-S37338356352009072100000) ).
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.
11. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the front wheel.