REMOVAL & INSTALLATION
| WARNING | Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury. |
| WARNING | Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. |
| WARNING | Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury. |
| CAUTION | Do not allow the brake master cylinder degas bottle to run dry during the bleeding operation. Keep the brake master cylinder degas bottle filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. |
- Disconnect accelerator pedal connector. (Scheme 1) Remove installation bolts. Remove pedal.
- Install in the reverse order of removal. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000).
Scheme 1
- Remove in the order indicated in the illustration. (Scheme 2)
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000).
Scheme 2
- Remove the battery and battery tray. See «BATTERY & BATTERY TRAY»(ref-164682-S11609097292004081600000).
- Disconnect the brake pipe (master cylinder side).
- Remove the accelerator pedal. See «ACCELERATOR PEDAL»(ref-164682-S25241826462004081600000).
- Remove components in the order indicated in the illustration. (Scheme 3)
- Install in the reverse order of removal. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Joint Pin Installation Note Install the new joint pin by aligning the pin holes of the brake pedal and power brake unit fork. (Scheme 4) Verify that the joint pin touches the power brake unit fork completely. Brake Switch Installation Note Inspect the brake pedal. With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal. Secure the brake switch by turning it counterclockwise 45 degrees. (Scheme 5)
Scheme 3
Scheme 4
Scheme 5
Note. Letters in parenthesis refer to letters in illustration.
- Detach clips (A), (B) and (C) and remove the upper panel. (Scheme 6)
- Detach clips (D), (E) and (F) and remove the boot panel. (Scheme 7)
- Remove screws (A). Detach clips (G). Disconnect the cigarette lighter connector. Remove the ashtray illumination, then remove the ashtray panel. (Scheme 8)
- Remove the screws (B). Detach tabs (H) and remove the console. (Scheme 9)
- To install, reverse removal procedure.
Scheme 6
Scheme 7
Scheme 8
Scheme 9
- Raise and support front of vehicle. Remove front wheel assemblies. Remove in the order indicated in the illustration. (Scheme 10) NOTE: It is not necessary to remove the disc plate to remove caliper.
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000). NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. If disc plate was removed, install the disc plate and align the marks made before removal. NOTE: Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 11) Install the disc pads.
Scheme 10
Scheme 11
- Raise and support front of vehicle. Remove front wheel assemblies. Remove in the order indicated in the illustration. (Scheme 10)
- Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164682-S15556567312004081200000).
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000). NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 11) To install the disc pad. After installation, pump the brake pedal a few times and verify that the brakes do not drag.
- Raise and support front of vehicle. Remove front wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 12)
- Replace pad if lining thickness is less than specified. See «DISC BRAKE SPECIFICATIONS»(ref-164682-S15556567312004081200000).
- To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. (Scheme 11) Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). After installation, pump the brake pedal a few times and verify that the brakes do not drag.
Scheme 12
- Remove the battery and battery tray. See «BATTERY & BATTERY TRAY»(ref-164682-S11609097292004081600000).
- Remove components in the order indicated in the illustration. (Scheme 13) CAUTION: Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid. NOTE: Remove the reserve hose from the reserve tank while pressing the point indicated by the arrow in the illustration. (Scheme 14)
- Install in the reverse order of removal. Tighten components to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000). NOTE: Insert the reserve hose to the reserve tank until a click is heard. Verify that the reserve hose is firmly installed by pulling it, and push it into the reserve tank again.
Scheme 13
Scheme 14
- Remove the exhaust pipe, main silencer. Remove the heat insulator.
- Remove the console. See «CONSOLE»(ref-164682-S37708340032004081200000).
- Remove the rear seat cushion.
- Remove components in the order indicated in the illustration. (Scheme 15)
- To install, reverse removal procedure.
- Adjust the parking brake stroke. See «PARKING BRAKE»(ref-164682-S33869050772004081200000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system if necessary. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000).
Front Parking Brake Cable Installation Note - Install the front parking brake cable with the mark on the equalizer facing toward the vehicle downside. (Scheme 16)
Rear Parking Brake Cable Installation Note - Pass the rear parking brake cable inside the rear ABS wheel-speed sensor wiring harness as shown in the illustration. (Scheme 17) Install the rear parking brake cable.
Scheme 15
Scheme 16
Scheme 17
- Remove the battery and battery tray. See «BATTERY & BATTERY TRAY»(ref-164682-S11609097292004081600000).
- Remove master cylinder. See «MASTER CYLINDER»(ref-164682-S13784167662004081200000).
- Remove the brake switch connector. Remove the accelerator pedal. See «ACCELERATOR PEDAL»(ref-164682-S25241826462004081600000).
- Remove components in the order indicated in the illustration. (Scheme 18)
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164682-S04779945162004081200000).
- After installation, adjust the brake pedal if necessary. See BRAKE PEDAL FREE PLAY and or BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH under «ADJUSTMENTS»(ref-164682-S30126044092004081200000).
Scheme 18
- Raise and support vehicle. Remove rear wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 19) NOTE: It is not necessary to remove the disc plate to remove caliper.
- To install, reverse removal procedure. For disc pad installation see, «REAR BRAKE PADS»(ref-164682-S20117746082004081200000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). After installation, depress the pedal several times, rotate the wheel by hand, verify that the brake does not drag, and then verify the parking brake stroke. See «PARKING BRAKE»(ref-164682-S33869050772004081200000) under ADJUSTMENTS. NOTE: Remove any rust or grime on the contact face of the disc plate and wheel hub. If disc plate was removed, install the disc plate.
Scheme 19
Removal
- Raise and support rear of vehicle. Remove rear wheel assemblies.
- Remove in the order indicated in the illustration. (Scheme 20)
Disc Pad Removal Note - Remove the disc pad (outer side) from the mounting support. Pull the disc pad (inner side) in the direction of the arrow to remove it from the caliper as shown in the illustration. (Scheme 21)
Installation
To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . After installation, depress the pedal several times, rotate the wheel by hand, verify that the brake does not drag, and then verify the parking brake stroke. See PARKING BRAKE under ADJUSTMENTS.
Disc Pad Installation Note
- Install the disc pad (outer side) to the mounting support. Clean the exposed area of the piston. Rotate the piston clockwise slowly using the Caliper Socket (49-F043-002) and socket wrench and push the piston inwards completely. (Scheme 22)
- Align the disc pad (inner side) spring into the piston groove, and insert it in the direction of the arrow. (Scheme 23) Install the disc pad (inner side) to the caliper.
Scheme 20
Scheme 21
Scheme 22
Scheme 23
- Raise and support vehicle. Remove rear wheel assemblies. Remove components in the order indicated in the illustration. (Scheme 19)
- Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See «DISC BRAKE SPECIFICATIONS»(ref-164682-S15556567312004081200000).
- To install, reverse removal procedure. For disc pad installation see, «REAR BRAKE PADS»(ref-164682-S20117746082004081200000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164682-S31555448232004081200000). After installation, depress the pedal several times, rotate the wheel by hand, verify that the brake does not drag, and then verify the parking brake stroke. See «PARKING BRAKE»(ref-164682-S33869050772004081200000) under ADJUSTMENTS.