REMOVAL & INSTALLATION
Refer to Brake Pads Removal and Installation procedure in this section. Remove both guide pins, torque member fixing bolts and brake hose connector. The brake system must be bled refer to the necessary procedure.
You should be able to check the pad lining thickness without removing the pads. Check the Brake Specifications chart at the end of this section to find the manufacturer's pad wear limit. However, this measurement may disagree with your state inspection laws. When replacing pads, always check the surface of the rotors for scoring or wear. The rotors should be removed for resurfacing if badly scored.
Types N20, N22, N22A, N32 and N34L Caliper
- With the vehicle supported safely and the front wheels off, remove the brake fluid tube from the caliper assembly.
- Remove the caliper from the knuckle assembly by removing the mounting bolts, located at the rear of the caliper, and lifting the caliper from the rotor.
- Remove the pads from the caliper (refer to the pad removal procedure).
- Remove the gripper pin attaching nuts and separate the yoke from the cylinder body.
- Remove the yoke holder from the piston and remove the retaining rings and dust seals from the ends of both pistons.
- Apply air pressure gradually into the fluid chamber of the caliper, to force the pistons from the cylinders.
- Remove the piston seals.
- Inspect the components for damage or excessive wear. Replace or repair as needed.
- To assemble, install the piston seals in the cylinder bore. Lubricate seals and pistons.
- Slide the A piston into the cylinder, followed by the B piston so that its yoke groove coincides with the yoke groove of the cylinder.
- Install the dust seal and clamp tightly with the retaining ring.
- Install the yoke holder on the A piston and install the gripper to yoke.
The use of soapy water will aid in the installation of the gripper pins.
- Support the end of B piston and press the yoke into the yoke holder.
- Install the pads, anti squeal springs, pad pins and retain with the clip.
- Tighten the gripper pin attaching nuts to 12-15 ft. lbs. and install the caliper on the spindle knuckle. Tighten the caliper mounting bolts to 53-72 ft. lbs.
- Bleed the system, check the fluid level, install the wheels and lower the vehicle.
- Remove the pads.
- Disconnect the brake tube.
- Remove the two bottom strut assembly installation bolts to provide clearance.
- Remove the caliper assembly mounting bolts.
- Loosen the bleeder screw and press the pistons into their bores.
- Clamp the yoke in a vise and tap the yoke head with a hammer to loosen the cylinder. Be careful that the primary piston does not fall out.
- Remove the bias ring from the primary piston. Remove the retaining rings and boots from both pistons. Depress and remove the pistons from the cylinder. Remove the piston seal from the cylinder carefully with the fingers so as not to mar the cylinder wall.
- Remove the yoke springs from the yoke.
- Wash all parts with clean brake fluid.
- If the piston or cylinder is badly worn or scored, replace both. The piston surface is plated and must not be polished with emery paper. Replace all seals. The rotor can be removed and machined if scored, but final thickness must be at least 8.5mm. Runout must not exceed 0.025mm.
- Lubricate the cylinder bore with clean brake fluid and install the piston seal.
- Insert the bias ring into primary piston so that the rounded ring portion comes to the bottom of the piston. Primary piston has a small depression inside, while secondary does not.
- Lubricate the pistons with clean brake fluid and insert into the cylinder. Install the boot and retaining ring. The yoke groove of the bias ring of primary piston must align with the yoke groove of the cylinder.
- Install the yoke springs to the yoke so the projecting portion faces to the disc (rotor).
- Lubricate the sliding portion of the cylinder and yoke. Assemble the cylinder and yoke by tapping the yoke lightly.
- Replace the caliper assembly and pads. Tighten the mounting bolts to 33-41 ft. lbs. Rotor bolt torque is 20-27 ft. lbs. Strut bolt torque is 33-44 ft. lbs. Bleed the system of air.
- Remove the brake pads.
- Disconnect the brake hose.
- Remove the cotter pins from the hold-down and pivot pins. Remove the retaining nuts.
- Remove the caliper plate from its mounting bracket.
- Remove the torsion spring and remove the cylinder assembly from the caliper plate.
- Apply air into the fluid chamber of the caliper and force the piston from the cylinder.
- Remove the wiper seal and piston seal retainer.
- Inspect the components for abnormal wear or damage. Repair or replace as necessary.
- Fit the seal into its groove in the cylinder. Lubricate the seal and piston. Install the piston into the cylinder.
- Place the caliper plate over the cylinder assembly and install the torsion spring.
- Install the caliper plate on the mounting bracket and install the nuts and cotter pins.
- Bleed the system and check the reservoir level.
- Disconnect and plug the brake line.
- Unscrew the two mounting bolts and remove the caliper.
- Remove the main pin and the sub pin and then separate the cylinder body from the torque member.
- Remove the piston dust cover.
- Apply compressed air gradually to the fluid chamber until the piston pops out.
- Carefully pry out the piston seal.
- Inspect the components for damage or excessive wear. Replace or repair as necessary.
- Install the piston seal in the cylinder bore. Lubricate the seals and pistons.
- Fit the dust seal onto the piston, insert the dust seal into the groove on the cylinder body and then install the piston.
- Place the cylinder body and torque member together, grease the main and sub pins, install the pins and tighten them to 12-15 ft. lbs. (16-21 Nm) on the CL22V, and 23-30 ft. lbs. on the AD22V.
- Install the caliper and tighten the mounting bolts to 36-51 ft. lbs. (46-69 Nm) on the CL22V, and 53-72 ft. lbs. on the AD22V. Reconnect the brake line and install the wheels.
- Bleed the system, check the fluid level and lower the vehicle.
- Remove the brake pads. Disconnect the brake hose and plug the open end of the hose. Remove the two caliper mounting bolts and remove the caliper.
- Place a wooden block between the caliper piston and the pad retainer opposite it. Then, gently apply compressed air to the brake hose connection. This will remove the piston and dust seal. Note the direction in which the piston seal is installed.
- Clean all parts in clean brake fluid. Inspect the inner cylinder bore for rust, scoring, or mechanical wear. Remove minor imperfections with emery paper. Replace the caliper body if these imperfections cannot be removed. Inspect the piston for such imperfections. If they exist, it must be replaced, as the surface is polished!
- Inspect the lockpins, bolts, piston seal, bushings, and pin seals for damage and replace all parts as necessary.
- Insert the piston seal into the groove on the caliper body. Install the inner edge of the rubber boot into the piston groove and then install the piston. Work the edge of the rubber boot into the groove in the caliper body.
- Perform the remaining procedures in the reverse of removal. Tighten the caliper mounting pins to 53-72 ft. lbs. Refill the system with clean brake fluid and bleed it thoroughly. Make sure you pump the brakes and get a hard pedal before operating the car.