BRAKE PAD REPLACEMENT - EXCEPT RALLIART
Required Special Tool
- MB990520: Disc Brake Piston Expander
REMOVAL AND INSTALLATION
| CAUTION | Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them. |
Scheme 21
>> A << VACUUM HOSE INSTALLATION
Align the mark as shown in the illustration to assemble the vacuum hose.
Scheme 22
Align the mark as shown in the illustration to assemble the vacuum hose.
Scheme 23
<< A >> PISTON BOOT/PISTON REMOVAL
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
<< B >> PISTON SEAL REMOVAL
| CAUTION | Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder. |
Scheme 24
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
Scheme 25
Scheme 26
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.
Scheme 27
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
| CAUTION | Do not use a flat-tipped screwdriver to remove the piston seal. This may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
Scheme 28
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the top.
Scheme 29
| CAUTION | Blow air little by little to remove the pistons. The pistons will rush out if a force of air is applied suddenly. If one piston has been removed completely, it will become impossible to remove the second piston. |
Remove the pistons and the piston boots by pumping in air from the brake hose connection. Be sure to use the handle of a plastic hammer and adjust the height of the two pistons so that the pistons protrude evenly.
Scheme 30
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT 3 or DOT 4
Scheme 31
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
Scheme 32
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.
Scheme 33
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
Scheme 34
Note. Install the brake pad assembly (with wear indicator) to the inner side of the brake disc, making sure that the wear indicator is located on the bottom.
Scheme 35
Scheme 36
| CAUTION | Blow air gradually to remove the pistons. The pistons will rush out if a force of air is applied suddenly. |
Cover the caliper body outer side with a cloth or similar materials. Blow compressed air through the brake hose installation area to remove the piston and piston boot.
| CAUTION | Do not use a flat-tipped screwdriver or similar tool to remove the piston seal. These may damage the inner side of the cylinder. |
- Remove the piston seal with your finger tip.
- Clean the piston surface and cylinder inner face with alcohol or specified brake fluid.
Brake fluid: DOT3 or DOT4
| CAUTION | Do not disassemble the rear wheel hub assembly. The magnetic encoder collects metallic particles easily, because it is magnetized. Make sure that the magnetic encoder should not collect metallic particles. Check that there is not any trouble prior to reassembling it. When the rear wheel hub assembly is removed/installed, make sure that the magnetic encoder (integrated with inner oil seal) does not contact with surrounding parts to avoid damage. When removing and installing the rear wheel speed sensor, make sure that its pole piece at the end does not contact with surrounding parts to avoid damage. The part indicated with * is the bolt with friction coefficient stabilizer. In removal, replace it with a new one. |
Scheme 37
<< A >> PARKING BRAKE REAR CABLE REMOVAL
Withdraw the parking brake cable from the backing plate.
Note. Insert a 10 mm-wrench into the parking brake cable to facilitate the cable withdrawal.
Scheme 38
<< B >> RETAINER REMOVAL
Use a flat-tipped screwdriver or a similar tool to open up the retainer joint. Then remove the retainer.
Scheme 39
>> A << RETAINER INSTALLATION
Use pliers or a similar tool to close the retainer end onto the pin.
Scheme 40
Scheme 41
Required Special Tool
- MB990619: Installer
Scheme 42
- Use alcohol or brake fluid DOT3 or DOT4 to clean the wheel cylinder and the piston. CAUTION: In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down special tool installer (MB990619) slowly and carefully, without stopping.
- Apply brake fluid DOT3 or DOT4 to the piston cups and special tool installer (MB990619).
- Set the piston cup on special tool with the lip of the cup facing up. Fit the cup onto special tool, and then slide it down the outside of special tool into the piston groove.