Honda Pilot - 2003-2005

Brake Disc (Rotor)

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Use a siphon or clean turkey baster to remove about half of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle and remove the tire/wheel assembly.
  4.  
  5. Remove the caliper guide pin or mounting bolts.
  6.  
  7. Lift the caliper assembly away from the brake rotor.
  8.  
  9. Use a suitable piece of wire to suspend the caliper assembly from the upper control arm. This will prevent the weight of the caliper from being supported by the brake flex hose which will damage the hose.
  10.  
  11. If equipped, remove the rotor retaining screws.
  12.  
  13. Remove the brake rotor by pulling it straight off the wheel mounting studs.
  14.  

To install:

  1. Retract the caliper piston into the cylinder.
  2.  
  3. Install the brake rotor onto the wheel hub.
  4.  
  5. Install the caliper assembly over the brake rotor and install the guide pin or mounting bolts.
  6.  
  7. Fill the master cylinder to the proper level with fresh brake fluid.
  8.  
  9. Install the tire/wheel assembly and lower the vehicle.
  10.  
  11. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
    CAUTION
    Do not move the vehicle until a firm pedal is obtained.

  12.  
  13. Road test the vehicle to check for proper brake operation.
  14.  

 
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