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    1964 International Truck Scout 2.5L 1BL 4cyl

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    Honda - Accord Prelude 1996 2000

    Brake Disc (Rotor)

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    REMOVAL & INSTALLATION



    Except 1996-97 Accord


    Click image to see an enlarged view

    Fig. After removing the caliper body, unfasten the retaining bolts and remove the caliper mounting bracket, in order to remove the rotor

    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 mounting bolts, then lift the caliper assembly away from the brake rotor.
    6.  
    7. Use a suitable piece of wire to suspend the caliper assembly. This will prevent the weight of the caliper from being supported by the brake flex hose which will damage the hose.
    8.  
    9. Once the caliper body and brake pads are removed, unfasten the caliper bracket mounting bolts, then remove the bracket from the rotor.
    10.  
    11. Remove the rotor retaining screws.
    12.  
    13. Remove the brake rotor by pulling it straight off the wheel mounting studs or if seized in place, remove the stubborn brake rotor by threading in two 8 x 1.25mm bolts, two turns at a time until the brake rotor is released.
    14.  

    To install:

    1. If necessary, completely retract the piston into the caliper using a large C-clamp or other suitable tool as provided in the front disc brake pad replacement procedures in this section.
    2.  
    3. Install the brake rotor onto the wheel hub and tighten the mounting screws.
    4.  
    5. Install the caliper mounting bracket and secure with the retaining bolts.
    6.  
    7. Install the caliper and pad assembly over the brake rotor and mounting bracket and install the mounting bolts.
    8.  
    9. Fill the master cylinder to the proper level with fresh brake fluid.
    10.  
    11. Install the tire/wheel assembly and lower the vehicle.
    12.  
    13. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
    14.  


    CAUTION
    Do not move the vehicle until a firm pedal is obtained.

    1. Road test the vehicle to check for proper brake operation.
    2.  

    1996-97 Accord


    Click image to see an enlarged view

    Fig. Use a prybar to hold the rotor while removing the attaching bolts



    Click image to see an enlarged view

    Fig. Once all of the bolts have been removed, pull the hub from the rotor

    1. Remove the knuckle/hub assembly from the vehicle. See Section 8 for this procedure.
    2.  
    3. Detach the hub from the unit.
    4.  
    5. Remove the splash guard from the knuckle.
    6.  
    7. Remove the four flange bolts
    8.  
    9. Pull the hub from the brake rotor.
    10.  

    To install:

    1. Installation is the reverse of removal. Refer to Section 8 for knuckle/hub assembly procedures.
    2.  
    3. Tighten the spindle nut to 181 ft. lbs. (245 Nm).
    4.  
    5. Torque the wheel lug nuts to 80 ft. lbs. (108 Nm).
    6.  

    INSPECTION





    Click image to see an enlarged view

    Fig. Measuring brake disc runout



    Click image to see an enlarged view

    Fig. Measuring brake disc thickness

    Whenever the brake calipers or pads are removed, inspect the rotors for defects. The brake rotor is an extremely important component of the brake system. Cracks, large scratches or warpage can adversely affect the braking system, at times to the point of becoming very dangerous.

    Light scoring is acceptable. Heavy scoring or warping will necessitate refinishing or replacement of the disc. The brake disc must be replaced if cracks or burned marks are evident.

    If the rotor needs to be replaced with a new part, the protective coating on the braking surface of the rotor must be removed with an appropriate solvent before installing the rotor to the vehicle.

    Check the run-out of the hub (disc removed). It should not be more than 0.002 inch (0.050mm). If so, the hub should be replaced.

    All brake discs or rotors have markings for MINIMUM allowable thickness cast on an unmachined surface or an alternate surface. Always use this specification as the minimum allowable thickness or refinishing limit. Refer to a local auto parts store or machine shop, if necessary, where rotors are resurfaced.

    If the rotor needs to be replaced with a new part, the protective coating on the braking surface of the rotor must be removed with an appropriate solvent before installing the rotor to the vehicle.

    To properly check a brake rotor, the disc runout, thickness and parallelism should be measured. To perform these measurements proceed as follows:

    1. Raise and safely support the vehicle.
    2.  
    3. Remove the tire/wheel assembly for the brake rotor to be inspected.
    4.  
    5. Reinstall the lug nuts and torque to 80 ft. lbs. (108 Nm).
    6.  
    7. Remove the brake pads as outlined in this section.
    8.  
    9. Inspect the brake surface for cracks and damage, then thoroughly clean the brake surface.
    10.  
    11. To measure runout:
      1. Attach a dial indicator to a solid portion of the suspension.
      2.  
      3. Set and zero the dial indicator plunger 0.40 inches (10mm) inside the outer circumference of the brake rotor.
      4.  
      5. Rotate the brake rotor and note the amount of runout by reading the dial indicator. If the runout exceeds 0.004 inches (0.10mm), measure the minimum thickness. If rotor thickness is within specification, use an approved on-car brake lathe and machine the brake rotor.
      6.  

    12.  
    13. To measure the brake rotor thickness and parallelism proceed as follows:
      1. Use a micrometer and measure the brake rotor thickness 0.40 inches (10mm) inside the outer circumference of the brake rotor every 45° ( 1 / 8 of a rotation).
      2.  
      3. Compare the smallest value measured to the minimum thickness specifications stamped on the brake rotor. If the rotor is below the minimum thickness, the rotor must be replaced. If within specification, measure the parallelism.
      4.  
      5. To measure parallelism, subtract the smallest value measured from the largest value measured. If the parallelism is greater than 0.0006 inches (0.015mm), use an approved on car brake lathe and machine the brake rotor.
      6.  

    14.  

    If after machining the brake rotor is below minimum thickness, it must be replaced.

     
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