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. |
| CAUTION | 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. |
- Remove components in the order indicated in the illustration. (Scheme 1)
- Install in the reverse order of removal. Install the new brake switch to the brake pedal Manual Transmission (MT) or the interlock cable Automatic Transmission (AT), and secure it by turning it clockwise 45 degrees A/T or counterclockwise 45 degrees M/T. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000).
Scheme 1
Scheme 2
Interlock Cable Installation Note
Note. Letters in parenthesis refer to letters in illustration.
- Push the snap pin into hole (A) by fully pushing the slider pin in. (Scheme 3)
- Push the snap pin into hole (B) and hole (C) of the lock unit until it passes through.
- Disconnect the brake switch connector.
- Remove the brake switch.
- Install the new brake switch. CAUTION: Do not connect the brake switch connector until the interlock cable is installed.
- With the slider pin pressed, slide the lock unit to fix the lock unit hook into the bracket hole securely as shown in the illustration. (Scheme 4) CAUTION: Allowing the interlock cable to be bent or twisted during installation can affect the lock unit operation.
- Rotate the slider pin to release the lock, and verify that it slides freely.
- Pull the slider pin outward until it contacts the brake pedal stopper rubber and rotate the slider pin to lock. (Scheme 5)
- Verify that the shift the selector lever in PARK position.
- Install the interlock cable end to the cam pin on the selector lever. (Scheme 6)
- Fit the interlock cable in the U-groove in the selector lever base plate, and install the clip. (Scheme 6)
- Press the interlock cable lock piece in until it is locked. (Scheme 7) CAUTION: Applying a load to the interlock cable while pressing the lock piece in can affect the lock unit operation.
- Remove the snap pin from the lock unit hole "A", "B" and "C". (Scheme 3)
- Connect the brake switch connector with the brake pedal released. CAUTION: The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch connector is connected after the brake switch has been properly installed. If the brake switch is not properly installed or the connector is connected before installation, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake switch is properly installed before connecting the connector. Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.
- Turn the ignition switch to ON position.
- Install the interlock cable to the key cylinder.
- Slide the outer casing to the key cylinder, and insert the clip over the convex part of the outer casing. (Scheme 8)
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Scheme 8
- Disconnect the negative battery cable.
- Detach clips "A" and remove the upper panel. Disassemble in the order indicated in the illustration. (Scheme 9) NOTE: Remove the ashtray panel using a flatblade screwdriver wrapped with protective tape.
- To install, reverse removal procedure.
Scheme 9
- Raise and support front of vehicle. Remove front wheel assemblies. Remove in the order indicated in the illustration. (Scheme 10) It is not necessary to remove the retaining screw and rotor to remove caliper.
- To install, reverse removal procedure. Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 11) Install the disc pads. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164898-S21370777542004081800000). NOTE: Remove any rust or grime on the contact face of the rotor and wheel hub. If rotor was removed, install the rotor and align the marks made before removal.
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-164898-S17830438602004081800000).
- To install, reverse removal procedure. Push the piston fully inward using the Caliper Piston Expander (49-0221-600C). (Scheme 11) Install the disc pad. After installation, pump the brake pedal a few times and verify that the brakes do not drag. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164898-S21370777542004081800000). NOTE: Remove any rust or grime on the contact face of the rotor and wheel hub.
- 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-164898-S17830438602004081800000).
- 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-164898-S25166227052004081800000). After installation, pump the brake pedal a few times and verify that the brakes do not drag.
Scheme 12
- Remove components in the order indicated in the illustration. (Scheme 13) NOTE: Disconnect and plug brake lines at master cylinder to prevent entry of dirt and loss of fluid.
- Install in the reverse order of removal. On master cylinder installation, see «MASTER CYLINDER INSTALLATION NOTE»(ref-164898-S04439623052004082300000). Tighten components to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164898-S21370777542004081800000).
Scheme 13
Master Cylinder Installation Note
| CAUTION | If the master cylinder is installed at a slanted angle to the power brake unit, the master cylinder piston may jam against the push rod retainer of the power brake unit, causing improper air bleeding, brake drag or other malfunctions. Be sure to install the master cylinder at a level, perpendicular angle to the power brake unit. |
Note. Always install the gasket of the power brake unit push rod before performing measurement inspections or adjustments.
- Install the Adjustment Gauge (49-G043-001) on to the power brake unit. (Scheme 14) Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000).
- Using a vacuum pump, apply 19.7 in. Hg (66.7 kPa) of vacuum. (Scheme 15)
- Measure the dimension of "L" as shown in the illustration. (Scheme 14) Push rod length should be 0.902-0.913" (22.9-23.2 mm).
- If dimension "L" is not within the specification as shown, remove adjustment gauge and use Adjustment Gauge Wrench (49-B043-004) to adjust the length of the push rod while using Adjustment Gauge Rod (49-E043-003A) to keep the push rod from rotating. (Scheme 16)
- Remove the adjustment gauge wrench and adjustment gauge rod, replace adjustment gauge and measure dimension "L" again. If incorrect readjust push rod depth.
- Install the master cylinder to the power brake unit. CAUTION: If after installing the master cylinder, air does not bleed properly from the brake lines even after performing air bleeding, brake drag occurs or other characteristics are present, it is possible that the master cylinder piston is jammed against the power brake unit. If air cannot be bled properly, brake drag exists or other malfunctions occur, remove the master cylinder and reinstall properly.
Scheme 14
Scheme 15
Scheme 16
- Remove the drive shaft. See DRIVE SHAFT under REMOVAL & INSTALLATION in appropriate DRIVE SHAFT & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- Remove the front console. See «CONSOLE»(ref-164898-S05555172112004081800000).
- Remove components in the order indicated in the illustration. (Scheme 17)
- To install, reverse removal procedure.
- Adjust the parking brake stroke if necessary. See «PARKING BRAKE»(ref-164898-S18712529572004081800000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000).
Scheme 17
- Remove master cylinder. See «MASTER CYLINDER»(ref-164898-S31639508832004081800000).
- 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-164898-S25166227052004081800000). Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-164898-S21370777542004081800000).
- After installation, adjust the brake pedal if necessary. See BRAKE PEDAL FREE PLAY and or BRAKE PEDAL HEIGHT & STOPLIGHT SWITCH under «ADJUSTMENTS»(ref-164898-S08856533162004081800000).
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 rotor to remove caliper. NOTE: If the rotor is to be removed, prior to removal, mark the wheel hub bolt and rotor before removal for reference during installation. (Scheme 20)
- To install, reverse removal procedure. For disc pad installation see, «REAR BRAKE PADS»(ref-164898-S35494314272004081800000). For caliper installation, see «CALIPER INSTALLATION NOTE»(ref-164898-S21182552962004082300000). For parking brake cable installation, see «PARKING BRAKE CABLE INSTALLATION NOTE»(ref-164898-S34503794942004082300000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). 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-164898-S18712529572004081800000) under ADJUSTMENTS. NOTE: Remove any rust or grime on the contact face of the rotor and wheel hub. If rotor was removed, install the rotor. Install the rotor and align the marks made before removal.
Scheme 19
Scheme 20
Caliper Installation Note
- Clean the exposed area of the piston.
- Rotate the piston clockwise slowly using the Caliper Piston Socket (49-F043-002) and push the piston completely until the piston grooves are in the position shown in the illustration. (Scheme 21)
- Install the caliper.
Scheme 21
Parking Brake Cable Installation Note
After installing the parking brake cable, verify that the operating lever returns to the stopper nut with the parking brake lever released. (Scheme 22)
Scheme 22
Scheme 22: Parking Brake Cable Installation Note
- Raise and support rear of vehicle. Remove rear wheel assemblies.
- Remove in the order indicated in the illustration. (Scheme 23) NOTE: When installing the caliper. Clean the exposed area of the piston. Rotate the piston clockwise slowly using the Caliper Piston Socket (49-F043-002) and push in the piston completely until the piston grooves are in the position as shown in the illustration. (Scheme 21) It is not necessary to completely remove caliper from brake assembly to rotate piston.
- To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). 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-164898-S18712529572004081800000) under ADJUSTMENTS. Ensure the disc pad projection is securely installed to the piston groove.
Scheme 23
- Raise and support vehicle. Remove rear wheel assemblies. Prior to removal, mark the wheel hub bolt and rotor before removal for reference during installation. (Scheme 20) 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-164898-S17830438602004081800000).
- To install, reverse removal procedure. For disc pad installation see, «REAR BRAKE PADS»(ref-164898-S35494314272004081800000). For caliper installation, see «CALIPER INSTALLATION NOTE»(ref-164898-S21182552962004082300000). For parking brake cable installation, see «PARKING BRAKE CABLE INSTALLATION NOTE»(ref-164898-S34503794942004082300000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-164898-S25166227052004081800000). After installation, ensure that the disc pad projection is securely installed to the piston groove, then 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-164898-S18712529572004081800000) under ADJUSTMENTS. NOTE: Prior to rotor installation, remove any rust or grime on the contact face of the rotor and wheel hub. Install the rotor and align the marks made before removal.
