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Disc & Drum: Removal & Installation Subaru Forester SG

Mechanical - Hydraulic 41 illustrations ~3686 words

Removal

  1. Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel.
  2. Remove lock pin.
  3. Raise caliper body.
  4. Remove pad. If brake pad is difficult to remove, proceed as follows: Remove caliper body and fasten it provisionally to coil spring. Remove support. Place support in a vise between wooden blocks. (Scheme 7) Attach a rod of less than 0.47" (12 mm) diameter to the brake pad tongues that hold them in the support, and strike rod with a hammer to drive brake pad out of place. (Scheme 8) CAUTION: Always replace pads for both left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.
  5. Check pad thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000).

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Installation

  1. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  2. Apply a thin coat of Molykote AS880N to the frictional portion between pad and pad inner shim. (Scheme 9) CAUTION: Replace pad if there is oil or grease on it. Do not apply grease between outer pad and outer shim. Do not confuse the inner shim with the outer shim.
  3. Check disc rotor thickness and runout. See «INSPECTION»(ref-163288-S17069896892004062400000) under FRONT DISC BRAKE ROTOR.
  4. Install pads on support.
  5. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000). NOTE: If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
  6. Depress brake pedal several times. Check that brake fluid level is at MAX line.
  7. Install front wheel.

Scheme 9

Scheme 9
Scheme 9
  1. Set vehicle on a lift.
  2. Loosen wheel nuts.
  3. Jack-up vehicle and remove front wheel.
  4. Remove caliper body from housing and suspend it from the strut using a wire. (Scheme 10)
  5. Remove disc rotor. NOTE: If disc rotor seizes up within the hub, drive the disc rotor out by installing an 8 mm bolt in the 2 holes on the rotor. (Scheme 11)
  6. Clean mud and foreign particles from the caliper body assembly and support.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Install disc rotor.
  2. Install caliper body on housing. (Scheme 10) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  3. Install wheel.
  1. Set vehicle on a lift.
  2. Loosen wheel nuts.
  3. Jack-up vehicle and remove front wheel.
  4. Remove union bolt and disconnect brake hose from caliper body assembly. (Scheme 12) CAUTION: Do not spill brake fluid on painted surface. Wash it off immediately.
  5. Remove bolt securing lock pin to caliper body.
  6. Raise caliper body and move it towards the vehicle center to separate it from support.
  7. Remove support from housing. (Scheme 13) NOTE: Remove support only when replacing it or the rotor. It does not need to be removed when servicing the caliper body assembly.
  8. Clean mud and foreign particles from the caliper body assembly and support.
  9. Check caliper body and piston for uneven wear, damage or rust.
  10. Check rubber parts for deterioration.
  11. Repair or replace faulty parts.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
  1. Install support on housing. (Scheme 13) Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  2. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  3. Apply a thin coat of Molykote AS880N to the frictional portion between pad and inner shim. (Scheme 9) NOTE: Do not apply grease between outer pad and outer shim. Do not confuse the inner shim with the outer shim.
  4. Install pads on support.
  5. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  6. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000). Replace brake hose gaskets with NEW ones.
  7. Bleed air from brake system. See «BLEEDING PROCEDURES»(ref-163288-S16345969712004062400000) under BLEEDING BRAKE SYSTEM.
  1. Set vehicle on a lift.
  2. Loosen wheel nuts.
  3. Jack-up vehicle and remove rear wheel.
  4. Remove lock pin. (Scheme 14)
  5. Raise caliper body. NOTE: Do not disconnect the brake hose from the caliper body.
  6. Remove pad from support. (Scheme 15) NOTE: If brake pad is difficult to remove, see steps A - D under FRONT DISC BRAKE PADS.
  7. Check pad thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000). CAUTION: Always replace pads for both left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  2. Install pad on support. (Scheme 15)
  3. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000). NOTE: If it is difficult to push piston during pad replacement, loosen air bleeder to facilitate work.

Removal & Installation

  1. Lift vehicle and remove wheels.
  2. Remove 2 mounting bolts and remove disc brake assembly. (Scheme 16)
  3. Suspend disc brake assembly so that the hose is not stretched.
  4. Pull down and release the parking brake.
  5. Remove disc rotor. NOTE: If disc rotor is difficult to remove, try the following: Turn adjusting screw using a slot-type screwdriver until the brake shoe gets away enough from the disc rotor. (Scheme 17) If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8 mm bolt in the 2 holes on the rotor. (Scheme 18)
  6. To install, reverse removal order.
  7. Adjust the parking brake. See «PARKING BRAKE»(ref-163288-S42485856122004062400000) under ADJUSTMENTS.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Set vehicle on a lift.
  2. Loosen wheel nuts.
  3. Lift-up vehicle and remove wheels.
  4. Disconnect brake hose from caliper body assembly.
  5. Remove lock pin. (Scheme 19)
  6. Raise caliper body and move it towards the vehicle center to separate it from support.
  7. Remove support from housing. NOTE: Remove support only when replacing it or the rotor. It does not need to be removed when servicing the caliper body assembly.
  8. Clean mud and foreign particles from caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet at brake hose connector.
  9. Check caliper body and piston for uneven wear, damage or rust.
  10. Check rubber parts for deterioration.
  11. Repair or replace faulty parts.

Scheme 19

Scheme 19
Scheme 19
  1. Install disc rotor on hub.
  2. Install support on housing. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) .
  3. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  4. Install pads on support.
  5. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) .
  6. Connect brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) . CAUTION: The brake hose must be connected without any twist. Replace brake hose gaskets with NEW ones.
  7. Bleed air from brake system. See «BLEEDING PROCEDURES»(ref-163288-S16345969712004062400000) under BLEEDING BRAKE SYSTEM.
  1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove the wheel.
  2. Release parking brake.
  3. Remove brake drum from the brake assembly. NOTE: If it is difficult to remove the brake drum, remove the adjusting hole cover from the back plate, and then turn the adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum. (Scheme 20) If the brake drum is difficult to remove, drive it out by installing an 8 mm bolt into the bolt hole in the brake drum. (Scheme 21)
  4. Hold the hold-down pin by securing rear of back plate with your hand. (Scheme 22)
  5. Disconnect the hold-down cup from the hold-down pin by rotating the hold-down cup.
  6. Disconnect the lower shoe return spring from shoes. (Scheme 23)
  7. Remove the shoes one by one from the back plate with the adjuster. (Scheme 24) CAUTION: Be careful not to bend the parking brake cable excessively when removing the brake shoes.
  8. Disconnect the parking brake cable from parking brake lever.
  9. Remove the upper shoe return spring and adjusting spring from brake shoe.
  10. Measure lining thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000).
  11. If deformation or wear of back plate, shoe, and other components are notable, replace them.
  12. When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Clean the back plate and wheel cylinder.
  2. Apply brake grease Dow Corning Molykote No. 7439 (Part No. 003602001) to the portions as indicated (Scheme 25)
  3. Apply brake grease to adjusting screw and both ends of adjuster. (Scheme 26)
  4. Connect upper shoe return spring to shoes.
  5. Connect the parking brake cable to parking lever.
  6. While positioning the shoes (one at a time) in groove on wheel cylinder, secure shoes. (Scheme 24)
  7. Fix shoes by connecting hold-down cup to the hold-down pin.
  8. Connect the lower shoe return spring.
  9. Set the outside diameter of brake shoes less than 0.02-0.031" (0.5-0.8 mm) in comparison with the inside diameter of the brake drum.
  10. Install the drum. See «REAR BRAKE DRUM»(ref-163288-S36446239872004062400000).

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26
  1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks and remove wheel.
  2. Release parking brake. NOTE: If it is difficult to remove the brake drum, remove the adjusting hole cover from the back plate, and then turn the adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum. (Scheme 20) If the brake drum is difficult to remove, drive it out by installing an 8 mm bolt into the bolt hole in the brake drum. (Scheme 21)
  3. Remove brake drum from brake assembly.
  4. If the inside surface of the brake drum is streaked, correct the surface. If it is unevenly worn, tapered, streaked, or the outside surface of brake drum is damaged, correct or replace it.
  5. Measure the drum inner diameter. (Scheme 27) See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000).

Scheme 27

Scheme 27
Scheme 27
  1. Set the outside diameter of brake shoes less than 0.02-0.031" (0.5-0.8 mm) in comparison with the inside diameter of brake drum.
  2. Install drum.
  3. Install rear wheel.
  1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove wheel.
  2. Release parking brake.
  3. Remove brake drum from brake assembly. See «REAR BRAKE DRUM»(ref-163288-S36446239872004062400000).
  4. Remove brake shoe. See «REAR DRUM BRAKE SHOE»(ref-163288-S18073004612004062400000).
  5. Unscrew brake hose flare nut and disconnect brake hose. (Scheme 28)
  6. Remove hub. See REAR HUB ASSEMBLY under REMOVAL & INSTALLATION in appropriate REAR AXLE SHAFTS article in DRIVELINE/AXLES.
  7. Disconnect ABS sensor from back plate (only for vehicles equipped with ABS).
  8. Remove brake assembly. (Scheme 29)
  9. Remove the bolts installing the wheel cylinder on the back plate and remove wheel cylinder. (Scheme 30)

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Clean back plate and wheel cylinder.
  2. Install wheel cylinder on back plate and tighten bolts to specification. (Scheme 30) See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  3. Apply Dow Corning Molykote No. 7439 (Part No. 003602001) grease to the portions indicated. (Scheme 25)
  4. Install brake assembly on housing and tighten bolts to specification for installation of the back plate. (Scheme 29) See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  5. Install hub. See REAR HUB ASSEMBLY under REMOVAL & INSTALLATION in appropriate REAR AXLE SHAFTS article in DRIVELINE/AXLES.
  6. Connect brake hose and tighten flange nut to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  7. Connect ABS sensor to back plate (only for models equipped with ABS). Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  8. Apply Dow Corning Molykote No. 7439 grease to the adjusting screw and both ends of adjuster.
  9. Install brake shoe. See «REAR DRUM BRAKE SHOE»(ref-163288-S18073004612004062400000).
  10. Install brake drum. See «REAR BRAKE DRUM»(ref-163288-S36446239872004062400000).
  11. After installing brake assembly, bleed air from brake line. See «BLEEDING PROCEDURES»(ref-163288-S16345969712004062400000) under BLEEDING BRAKE SYSTEM.
  1. Lift-up vehicle.
  2. Remove the rear tire and wheel.
  3. Remove the rear seat cushion.
  4. Remove console box. Disconnect the ground terminal from battery. Remove the console cover. Remove the shift knob (MT model) and front cover. Loosen the screws to remove the console box.
  5. Loosen the parking cable adjusting nut and console bracket.
  6. Disconnect the connector of parking brake switch.
  7. Remove the parking brake lever. (Scheme 31)
  8. Unbend the parking brake lever pawls and remove cable. (Scheme 32)
  9. To install, reverse removal order. Tighten parking brake lever and the adjusting nut to specifications. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  10. Be sure to adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-163288-S07192427082004062400000) under PARKING BRAKE under ADJUSTMENTS.
  11. While pulling the parking brake lever upward, count the notches. The lever stroke should be 7-8 notches at a force of 44 lbs. (196 N). If incorrect adjust the parking brake. See «PARKING BRAKE»(ref-163288-S42485856122004062400000) under ADJUSTMENTS.

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32
  1. Lift-up vehicle.
  2. Remove rear tires and wheels.
  3. Remove rear cushion.
  4. Remove console box: Disconnect the ground terminal from battery. Remove the console cover. Remove the shift knob (MT model) and front cover. Loosen the screws to remove the console box.
  5. Loosen parking cable adjusting nut and console bracket.
  6. Remove parking brake lever. (Scheme 31)
  7. Roll up floor mat and remove clamps. (Scheme 33)
  8. Remove equalizer cover.
  9. Remove inner cable end from equalizer. (Scheme 34)
  10. Pull out parking brake cable from rear brake. See one of the following accordingly: See «PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)»(ref-163288-S17327052942004062400000). See «REAR DRUM BRAKE ASSEMBLY»(ref-163288-S39474817702004062400000).
  11. Pull out clamp from rear brake.
  12. Remove bolt and bracket from trailing link bracket.
  13. Remove bolt and clamp from rear floor. (Scheme 35)
  14. Detach grommet from rear floor.
  15. Remove cable assembly from cabin by forcibly pulling it backward.
  16. Detach parking brake cable from cable guide at rear trailer link.
  17. Inspect parking brake cable and replace it id damaged, rusty or malfunctioning: Check that cable operates smoothly. Check inner cable for damage and rust. Check outer cable for damage, bends or cracks. Check boot for damage, cracks or deterioration.
  18. Install NEW parking brake assembly in reverse order of removal.
  19. Be sure to pass cable through the cable guide inside tunnel. Adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-163288-S07192427082004062400000) under PARKING BRAKE under ADJUSTMENTS.

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35
  1. Pull down and release the parking brake.
  2. Remove 2 mounting bolts and remove disc brake assembly. (Scheme 16)
  3. Suspend disc brake assembly so that the hose is not stretched.
  4. Remove disc rotor. NOTE: If the disc rotor is difficult to remove, perform the following procedures: Turn the adjusting screw using a slot-type screw driver until the brake shoe gets away enough from the disc rotor. (Scheme 17) If disc rotor seizes up within the hub, drive the disc rotor out by installing an 8 mm bolt in the side holes on the rotor. (Scheme 18)
  5. Remove the primary and secondary return spring from the parking brake assembly.
  6. Remove the front shoe hold down spring and pin with pliers.
  7. Remove strut and strut spring.
  8. Remove adjuster assembly and adjusting spring from the parking brake assembly.
  9. Remove brake shoe.
  10. Remove rear shoe hold down spring and pin with pliers. (Scheme 36)
  11. Remove parking cable from parking lever. (Scheme 37)
  12. Using a standard screwdriver, raise the retainer. Remove the parking lever and washer from the brake shoe.
  13. Measure the brake disc inside diameter. See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000). If the disc is scored or worn, replace the brake disc.
  14. Measure the lining thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163288-S41336754872004062400000). If it exceeds the limit, replace the shoe assembly.

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
CAUTIONBe sure the lining surface is free from oil contamination.
  1. Apply Dow Corning Molykote No. 7439 (Part No. 003602002) brake grease to the following places: The 6 contact surfaces of shoe rim and back plate packing. Contact surface of shoe wave and anchor pin. Contact surface of lever and strut. Contact surface of shoe wave and adjuster assembly. Contact surface of shoe wave and strut. Contact surface of lever and shoe wave.
  2. Insert primary side brake shoe into anchor pin groove.
  3. Secure brake shoe with hold down pin and cup.
  4. Install the plate to anchor pin, and then assemble the primary return spring to anchor pin. (Scheme 38)
  5. Install the parking brake cable to the parking brake lever.
  6. Assemble the strut and adjuster, and then secure the secondary side brake shoe with shoe hold down pin and cup. NOTE: Install the strut spring of both right and left wheel facing vehicle front. Install the adjuster assembly with screw on left side. (Scheme 39)
  7. Install the secondary return spring and adjusting spring.
  8. Adjust the parking brake. See «PARKING BRAKE»(ref-163288-S42485856122004062400000) under ADJUSTMENTS.
  9. Drive the vehicle for parking brake lining break in. Drive the vehicle at about 22 MPH. With the parking brake release button pushed in, pull the parking brake lever gently. Drive the vehicle for about 0.12 mile (200 meters) in this condition. Wait 5 to 10 minutes for the parking brake to cool down. Repeat this procedure once more. After breaking in, re-adjust the parking brakes. See «PARKING BRAKE»(ref-163288-S42485856122004062400000) under ADJUSTMENTS.

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39
  1. Thoroughly drain brake fluid from reservoir tank.
  2. Disconnect fluid level indicator harness connector.
  3. Remove brake pipes from master cylinder.
  4. Remove master cylinder mounting nuts, and take master cylinder out from brake booster.
  5. To install, reverse removal procedures. Tighten the master cylinder mounting nut and the piping flare nut to specifications. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) . CAUTION: Be sure to use recommended brake fluid. See «BRAKE FLUID»(ref-163288-S20321301372004062400000) under BLEEDING BRAKE SYSTEM.
  6. Bleed air from the brake system. See «BLEEDING PROCEDURES»(ref-163288-S16345969712004062400000) under BLEEDING BRAKE SYSTEM.
  1. Remove or disconnect the following parts at the engine compartment: Disconnect the connector for brake fluid level indicator. Remove brake pipes from the master cylinder. Remove the master cylinder installing nuts. Disconnect vacuum hose from the brake booster.
  2. Remove the following parts from the pedal bracket: Remove snap pin and clevis pin. (Scheme 40) Remove four brake booster installing nuts. CAUTION: If external force is applied from above when brake booster is placed on its side, the resin portion may be damaged. (Scheme 41) NOTE: Be careful not to drop the brake booster. Brake booster should be discarded if it has been dropped. Use special care when handling the operating rod. If excessive force is applied to the operating rod, sufficient to cause a change in the angle in excess of 3 degrees, it may result in damage to the power piston cylinder. NOTE: Use care when placing the brake booster on the floor. Do not change the push rod length. If it has been changed, reset the projected length to the standard length. (Scheme 42) See «PUSH ROD SPECIFICATIONS»(ref-163288-S17245990342004062400000) table.
  3. Remove the brake booster while shunning brake pipes.

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42
ApplicationIn. (mm)
Push Rod0.396 (10.05)
Operating Rod5.69 (144.6)

BRAKE BOOSTER SPECIFICATIONS

  1. Adjust the operating rod of the brake booster. (Scheme 44) If it is not to specified length, adjust it by adjusting the brake booster operating rod. See «BRAKE BOOSTER SPECIFICATIONS»(ref-163288-S17245990342004062400000) table.
  2. Mount the brake booster in position.
  3. Connect the operating rod to the brake pedal with the clevis pin and the snap pin. (Scheme 40)
  4. Connect the vacuum hose to the brake booster. (Scheme 43)
  5. Mount the master cylinder onto brake booster.
  6. Connect the brake pipes to the master cylinder.
  7. Connect the electric connector for brake fluid level indicator.
  8. Measure the clearance between threaded end of stoplight switch and stopper. If stoplight switch clearance is not 0.012" (0.3 mm), adjust it by adjusting the position of the stoplight switch. (Scheme 45) CAUTION: Do not rotate the stoplight switch.
  9. Apply grease to operating rod connecting pin to prevent it from wearing.
  10. Bleed air from brake system. Tighten air bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000).
  11. Conduct road tests to ensure brakes do not drag.

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45
  1. Drain brake fluid from reservoir of master cylinder.
  2. Remove the adjusting nut and lock nut. see scheme 2
  3. Remove the cable clamp, and disconnect Pressure Hold Valve (PHV) cable from PHV. (Scheme 46) CAUTION: Carefully protect boots and inner cable from damage when disconnecting PHV cable.
  4. Disconnect the brake pipes from PHV. CAUTION: Do not drop brake fluid onto body painting since it may dissolve paint. Do not damage hexagonal head of the flare nut by using pipe wrench without fail.
  5. Detach PHV with support from side frame. (Scheme 47) CAUTION: Exercise utmost care to prevent foreign matter from entering into PHV when removing it.
  6. Check removed parts as follows and replace damaged parts. Checked if boots of PHV cable are damaged or degraded, the inner cable is damaged or corroded. Check if the return spring is worn out, damaged or corroded. Confirm that rolling sound of ball is heard with PHV inclined and lever rotates smoothly.

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47
  1. Install PHV onto side frame. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) .
  2. Connect brake pipes to PHV. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163288-S22820919132004062400000) . CAUTION: Confirm that brake pipes are not deformed and/or damaged. Replace them with NEW ones if necessary.
  3. Install PHV cable to PHV. CAUTION: If cable clamp and clips are damaged, replace them with NEW ones. Avoid sharp bending of PHV cable as it may cause breakage.
  4. Connect PHV cable with clips.
  5. Apply SUNLIGHT 2 (Part No. 003602010) grease to hook portion of return spring and cable end portion of lever.
  6. Bleed air from the brake system. See «BLEEDING PROCEDURES»(ref-163288-S16345969712004062400000) under BLEEDING BRAKE SYSTEM.
  7. Adjust PHV cable. See «HILL HOLDER»(ref-163288-S39498886152004063000000) under ADJUSTMENTS.
  1. Remove adjusting nut and lock nut.
  2. Remove the cable clamp, and disconnect PHV cable from PHV. CAUTION: Carefully protect the boot and inner cable from damage when disconnecting PHV cable.
  3. Remove clamp from clutch cable bracket.
  4. Remove PHV cable.
  5. Check removed parts as follows and replace damaged parts. Checked if boots of PHV cable are damaged or degraded, the inner cable is damaged or corroded. Check if the return spring is worn out, damaged or corroded. Confirm that rolling sound of ball is heard with PHV inclined and lever rotates smoothly.
  6. Install PHV cable in reverse order of removal. CAUTION: If cable clamp is damaged, replace it with a NEW one. Avoid sharp bending of PHV cable as it may cause breakage.
  7. Apply SUNLIGHT 2 (Part No. 003602010) grease to hook portion of return spring and cable end portion of lever.
  8. Adjust PHV cable. See «HILL HOLDER»(ref-163288-S39498886152004063000000) under ADJUSTMENTS.

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