Conventional Brake Components: Removal & Installation Honda S2000 AP1

Front Brake Disc Replacement

Note. Keep Any Grease Off The Brake Disc And Brake Pads.

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1. Raise The Front Of The Vehicle, And Support It With Safety Stands In The Proper Locations (See «Safety Stands»(ref-221314-S10900723812006022400000) ).
2. Remove The Front Wheel.
3. Remove The Brake Hose Bracket 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 Front Hub. NOTE: If The Brake Disc Is Stuck To The Front Hub, Thread Two 8 X 1.25 Mm Bolts (C) Into The Brake Disc To Push It Away From The Front Hub. 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 Surface Between The Front Hub And The Inside Of The Brake Disc.
8. Inspect The Brake Disc Runout (See «front Brake Disc Inspection»(ref-351950-S09103403342009122900000) ).
9. Clean The Mating Surfaces Between The Brake Disc And The Inside Of The Wheel, Then Install The Front Wheel.

Master Cylinder/Brake Booster 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.

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1. Disconnect The Brake Fluid Level Switch Connector.
2. Remove The Brake Fluid From The Master Cylinder Reservoir With A Syringe.
3. Disconnect The Brake Lines From The Master Cylinder. To Prevent Spills, Cover The Line Joints With Clean Rags Or Shop Towels.
4. Remove The Master Cylinder Mounting Nuts And Washers.
5. Remove The Master Cylinder From The Brake Booster. Be Careful Not To Bend Or Damage The Brake Lines When Removing The Master Cylinder.
6. Disconnect The Brake Booster Vacuum Hose From The Brake Booster.
7. Remove The Lock Pin And The Clevis Pin.
8. Remove The Four Brake Booster Mounting Nuts.
9. Pull The Brake Booster Forward, And Remove The Brake Booster From The Engine Compartment. Be Careful Not To Bend Or Damage The Brake Lines When Removing It.
10. Install The Brake Booster And Master Cylinder In The Reverse Order Of Removal, And Note These Items: Replace Parts With New Ones As Specified In The Illustration. Install The Rod Seal Onto The Brake Booster With Its Grooved Side Toward The Master Cylinder. '00-05 Models, Adjust The Pushrod Length Before Installing The Booster (See «master Cylinder Inspection»(ref-351950-S17260284002009122900000) ). Coat The Inner Bore Lip And 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 If Necessary (See «brake Pedal And Brake Pedal Position Switch Adjustment»(ref-351950-S27484223032009122900000) ). Bleed The Brake System (See «brake System Bleeding»(ref-351950-S24431453552009122900000) ). Spin The Wheels To Check For Brake Drag.

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1. Remove The Master Cylinder (See «master Cylinder/Brake Booster Replacement»(ref-351950-S06990154802009122900000) ).
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/Brake Booster Replacement»(ref-351950-S06990154802009122900000) ).

Rear Brake Disc Replacement

Note. Keep Any Grease Off The Brake Disc And Brake Pads.

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1. Raise The Rear Of The Vehicle, And Support It With Safety Stands In The Proper Locations (See «Safety Stands»(ref-221314-S10900723812006022400000) ).
2. Remove The Rear Wheel.
3. Release The Parking Brake Lever Fully.
4. Remove The Brake Caliper Bracket Mounting Bolts (A), Then 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 And The Parking Brake Cable Excessively.
5. Remove The Brake Disc Flathead Screws (A).
6. Remove The Brake Disc (B) From The Rear Hub. NOTE: If The Brake Disc Is Stuck To The Rear Hub, Thread Two 8 X 1.25 Mm Bolts (C) Into The Brake Disc To Push It Away From The Rear Hub. 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, And Note These Items: Before Installing The Brake Disc, Clean The Mating Surfaces Between The Hub Bearing Unit And The Inside Of The Brake Disc. Adjust The Parking Brake (See «adjustment»(ref-351950-S42745355012009122900000) ).
8. Inspect The Brake Disc Runout (See «rear Brake Disc Inspection»(ref-351950-S32135629062009122900000) ).
9. Clean The Mating Surfaces Between The Brake Disc And The Inside Of The Wheel, Then Install The Rear Wheel.

Rear Brake Caliper Removal/Installation

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1. Raise The Rear Of The Vehicle, And Support It With Safety Stands In The Proper Locations (See «Safety Stands»(ref-221314-S10900723812006022400000) ).
2. Remove The Rear Wheel.
3. Release The Parking Brake Lever Fully.
4. Remove The Caliper Shield (A).
5. Remove The Brake Hose Mounting Bracket (A) From The Rear Caliper Body.
6. Remove The Cable Clip (A) From The Parking Brake Cable (B).
7. Disconnect The Parking Brake Cable End From The Parking Brake Arm (C).
8. Remove The Banjo Bolt (A), And Disconnect The Brake Hose (B). Remove The Two Sealing Washers (C), And Replace Them. 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.
9. Remove The Flange Bolts (D) While Holding The Caliper Pins (E) With A Wrench. Be Careful Not To Damage The Pin Boot, And Remove The Caliper (F).
10. Install The Rear Brake Caliper In The Reverse Order Of Removal, And Note These Items: When Installing The Caliper, Align The Cutout In The Piston With The Tab On The Inner Pad (See «replacement»(ref-351950-S28959701422009122900000) ). Check The Brake Hose And Caliper Fitting For Leaks, And Tighten The Banjo Bolt If Necessary. Check The Brake Hoses For Interference And Twisting. Contaminated Brake Discs Or Pads Reduce Stopping Ability. Keep Paste Off Of The Discs And Pads. Bleed The Brake System (See «brake System Bleeding»(ref-351950-S24431453552009122900000) ). Adjust The Parking Brake (See «adjustment»(ref-351950-S42745355012009122900000) ).

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. Plug The Ends Of The Hoses And The Joints To Prevent Spilling Brake Fluid.

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1. Remove The Wheel.
2. Disconnect The Brake Hose (A) From The Brake Line (B) Using A 10 Mm Flare-Nut Wrench (C).
3. Remove 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 And Damper Bracket.
6. Install The Brake Hose (A) On The Knuckle And Damper Bracket With Two 6 Mm Flange Bolts (B) And The 8 Mm Flange Bolt (C) First, Then Connect The Brake Hose To The Caliper With The Banjo Bolt (D) And New Sealing Washers (E).
7. Install The Brake Hose (A) Onto The Upper Brake Hose Bracket (B) On The Body 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»(ref-351950-S24431453552009122900000) ).
10. Do The Following Checks: Check The Brake Hose And Line Joint For Leaks, And Tighten If Necessary (See «brake Hose And Line Inspection»(ref-351950-S34050059572009122900000) ). 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 Wheel.

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