FRONT DISC BRAKE ASSEMBLY
Note. Before disassembling and reassembling front disc brake assembly, identify the brakes components. (Scheme 45)
Scheme 45
Disassembly
- Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet at brake hose connector.
- Using a standard screwdriver, remove the boot ring from the piston. (Scheme 46)
- Remove the boot from the piston end.
- Gradually supply compressed air via caliper body brake hose to force piston out. CAUTION: Place a wooden block as shown to prevent damage to piston. (Scheme 47)
- Remove the piston seal from the caliper body cylinder. (Scheme 48)
- Remove the lock pin boot and guide pin boot. NOTE: Repair or replace faulty parts.
- Check caliper body and piston for uneven wear, damage or rust.
- Check the rubber parts for damage or deterioration.
Scheme 46
Scheme 47
Scheme 48
Assembly
- Clean the caliper body Interior using brake fluid.
- Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
- Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
- Insert piston into cylinder. (Scheme 49) CAUTION: Do not force piston into cylinder.
- Apply a coat of NIGLUBE RX-2 (Part No. 0036060000) grease to the boot and fit in the groove on ends of cylinder and piston. To facilitate installation, fit the boot starting with the piston end. (Scheme 50)
- Position boot in grooves on cylinder and piston.
- Install boot ring. Be careful not to scratch the boot.
- Apply a coat of NIGLUBE RX-2 grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves. (Scheme 51)
- Install lock pin boot and guide pin boot on support.
Scheme 49
Scheme 50
Scheme 51
REAR DISC BRAKE ASSEMBLY
Note. Before disassembling and reassembling rear disc brake assembly, identify the brakes components. (Scheme 52)
Scheme 52
- Remove boot ring. (Scheme 53)
- Remove piston boot.
- Gradually supply compressed air via inlet of caliper body to force piston out. CAUTION: Place a wooden block as shown to prevent damage to piston. (Scheme 47) Do not apply excessively high pressure.
- Remove piston seal from caliper body cylinder.
- Remove lock pin sleeve and boot from caliper body.
- Remove guide pin boot. NOTE: Repair or replace faulty parts.
- Check caliper body and piston for uneven wear, damage or rust.
- Check the rubber parts for damage or deterioration.
Scheme 53
- Clean caliper body interior using brake fluid.
- Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
- Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
- Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder.
- Apply a coat of NIGLUBE RX-2 (Part No. 003606000) grease to the boot and fit in the groove on ends of cylinder and piston.
- Install the piston boot to the caliper body, and attach boot ring. (Scheme 50)
- Apply a coat of NIGLUBE RX-2 grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. (Scheme 51)
- Install guide pin boot on caliper body.
- Install the lock pin boot on caliper body and insert lock pin sleeve into place.
REAR DRUM BRAKE ASSEMBLY
Note. Before disassembling and reassembling rear drum brake assembly, identify the brakes components. (Scheme 54)
Scheme 54
- Remove right and left dust boots from wheel cylinder. (Scheme 55)
- Remove the piston, cup, spring and air bleeder screw and cap.
- Inspect the wheel cylinder for leakage.
- If deformation or wear of back plate, shoe, and other components are notable, replace them.
- Measure lining thickness. See «REAR DRUM BRAKE SERVICE SPECIFICATIONS»(ref-162994-S06215687252004061600000) table under DRUM BRAKE SPECIFICATIONS.
- Measure the drum inner diameter. see scheme 27 See «REAR DRUM BRAKE SERVICE SPECIFICATIONS»(ref-162994-S06215687252004061600000) table under DRUM BRAKE SPECIFICATIONS.
Scheme 55
- Clean all parts with brake fluid. Check and replace faulty parts. Check cup and boot for damage or fatigue. Check cylinder, piston and spring for damage or rust formation.
- Assemble parts in reverse order of disassembly. When installing the cup, use ST, apply brake fluid to the frictional surface for smooth installation and pay attention to cup direction. (Scheme 56) ST's are available in different sizes. CAUTION: When replacing the repair kit, make sure that the sizes of cylinder and cup are the same as those which were replaced. Use only the 3/4" (19 mm) ST adapter tool (Part No. 926460000). CAUTION: While assembling, be careful to prevent any metal chip, dust or dirt from entering the wheel cylinder.
- Apply NIGLUBE RX-2 (Part No. 003606000) rubber grease to the boot inside as shown. (Scheme 57) CAUTION: Never use brake grease.
Scheme 56
Scheme 57
MASTER CYLINDER ASSEMBLY
Note. Before disassembling and reassembling master cylinder assembly, identify the master cylinder components. (Scheme 58)
Scheme 58
- Remove mud and dirt from the surface of the brake master cylinder.
- Prepare the tools necessary for disassembly operation, and arrange them neatly on work bench.
- Clean the work bench.
- Remove the pin with drift pin which secures the reserve tank to master cylinder.
- Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston. (Scheme 59)
- Pry up the pawl and remove the piston retainer. (Scheme 60) NOTE: Piston may jump out from master cylinder.
- Extract the primary piston assembly and secondary piston assembly. CAUTION: Do not disassemble the piston assembly; otherwise, the spring set value may be changed. Use brake fluid or methanol to wash inside wall of cylinder, piston and piston cups. Be careful not to damage parts when washing. If methanol is used for washing, do not dip rubber parts, such as piston cups, in it for more than 30 seconds; otherwise, they may become swelled.
- If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part. CAUTION: The primary and secondary pistons must be replaced as complete assemblies. The service limit of the clearance between each piston and the master cylinder inner diameter is 0.0043" (0.11 mm). When handling parts, be extremely careful not to damage or scratch the parts, or let any foreign matter get on them.
Scheme 59
Scheme 60
- When assembling, be sure to use recommended brake fluid. See «BRAKE FLUID»(ref-162994-S24412324762004061600000) under BLEEDING BRAKE SYSTEM.
- Ensure that the inside wall of cylinder, pistons, and piston cups are free from dirt when assembling.
- Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups.
- Do not drop the parts. Never attempt to use any part that has been dropped accidentally.
- To assemble the piston assembly, apply recommended brake fluid to inside wall of cylinder and to outer surface of piston assembly, and install the piston assemblies carefully into cylinder.
- To assemble the cylinder pin, perform the following procedures: Press the pawl and install the piston retainer into the master cylinder. (Scheme 60) Install the seal to reservoir tank. (Scheme 61) Install the pin with drift pins which secures the reservoir tank to master cylinder.
