Would anyone with a Helms manual be able to...
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Honkey
Joined: Jan 2001
Posts: 2,728
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From: Scottsdale, AZ
Would anyone with a Helms manual be able to...
Scan the pages that explain how to disassemble and reassemble the brake calipers and remove the brake rotors? I'm looking for info on removing the piston out of the caliper and such. Thanks in advance.
-Aaron
-Aaron
Sorry bud I cant get this crap ass scanner to work and my digi cam is at work. I tried 
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Originally Posted by beestea
Either of you guys still have that scan handy?
I am about to replace my brakes for the first time on any car, so pretty pictures would definitely come in handy.
Thanks!
I am about to replace my brakes for the first time on any car, so pretty pictures would definitely come in handy.
Thanks!
But it proves he knows how to search 
can't hate on him for that.
Instructor
Joined: Aug 2005
Posts: 116
Likes: 0
From: niantic ct
2003 BRAKES
Disc - 3.2CL & 3.2TL
DESCRIPTION & OPERATION
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Avoid spilling brake fluid on car, as it will damage paint. If brake fluid contacts paint, immediately flush with water.
All models are equipped with front and rear disc brakes. A cable operates parking brake at rear wheels. The parking brake uses drum brake shoes mounted inside rear disc brake rotor. See Fig. 1 .
Fig. 1: Locating Brake Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURE
CAUTION: Use only clean DOT 3 brake fluid. Ensure no dirt or other foreign matter contaminates brake fluid. DO NOT mix different brands of brake fluid, as they may not be compatible. Avoid spilling brake fluid on car, as it will damage paint. If brake fluid contacts paint, immediately flush with water.
CAUTION: DO NOT press brake pedal all the way to the floor. Press brake pedal half-way to avoid damage to master cylinder piston seal. Damage to piston seal can cause internal and/or external leaks.
Ensure master cylinder reservoir is full before performing bleeding procedure. Refill reservoir after bleeding each wheel. Have an assistant slowly pump brake pedal several times, then apply steady pressure. Loosen brake bleed screw at each wheel to allow air to escape from system. Tighten bleed screw to specification. See TORQUE SPECIFICATIONS . Repeat procedure until air bubbles no longer appear in fluid.
Bleed brakes in following sequence. See BRAKELINE BLEEDING SEQUENCE table. Ensure master cylinder reservoir is full. Road test vehicle and check brake performance.
BRAKELINE BLEEDING SEQUENCE
Application Sequence
3.2CL & 3.2TL LF, RF, RR, LR
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
Measure pedal height from right side center of pedal pad to floor panel, with carpet cutout turned up. See BRAKE PEDAL HEIGHT & FREE PLAY table. See Fig. 2 .
To adjust brake pedal height, disconnect stoplight switch. Loosen stoplight switch lock nut and back off switch until it no longer touches brake pedal. Loosen power brake booster push rod lock nut. Rotate push rod to adjust pedal height. Tighten lock nut to specification. See TORQUE SPECIFICATIONS .
Turn ignition switch to OFF position. Adjust stoplight switch. See STOPLIGHT SWITCH . See BRAKE PEDAL HEIGHT & FREE PLAY table.
BRAKE PEDAL HEIGHT & FREE PLAY
Application In. (mm)
Brake Pedal Free Play .04-.20 (1.0-5.0)
Brake Pedal Height (1)
3.2CL 6.63 (168.0)
3.2TL 6.65 (169.0)
(1) With carpet cutout turned up.
Fig. 2: Adjusting Brake Pedal Height & Free Play
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER PUSH ROD CLEARANCE
NOTE: Master cylinder push rod-to-piston clearance must be checked and adjusted before installing master cylinder.
Mount Push Rod Adjustment Gauge (07JAG-SD40100) on master cylinder. Rotate adjuster nut until top of center shaft contacts end of secondary piston without changing piston position. See Fig. 3 .
Remove push rod adjustment gauge from master cylinder, and install on brake booster. Tighten master cylinder nuts to specification. See TORQUE SPECIFICATIONS . Using engine or outside vacuum source, apply a continuous 20 in. Hg vacuum to brake booster.
Using a feeler gauge, ensure clearance between gauge body and adjusting nut is .02" (0.4 mm). See Fig. 4 .
Loosen star lock nut and rotate adjuster nut in or out to adjust clearance. Hold push rod, and rotate adjuster in or out for specified clearance. DO NOT pull push rod out of brake booster. Tighten star lock nut securely.
Fig. 3: Setting Push Rod Adjustment Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 4: Measuring Push Rod Clearance
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE
Adjustment Check (3.2CL M/T)
Pull parking brake lever with 66 lbs. (294 N) of force to fully apply parking brake. Parking brake lever should be locked with 6-10 clicks.
Adjustment Check (Except 3.2CL M/T)
Press parking brake pedal with 66 lbs. (294 N) of force. Parking brake pedal should lock with specified number of clicks. See PARKING BRAKE ADJUSTMENT CHECK table.
PARKING BRAKE ADJUSTMENT CHECK
Application No. Of Clicks For Parking Brake Lock
3.2CL
A/T (1) 2-4
M/T (2) 6-10
3.2TL (1) 2-4
(1) Press parking brake pedal with 66 lbs. (294 N) of force to fully apply parking brake.
(2) Pull parking brake pedal with 66 lbs. (194 N) of force to fully apply parking brake.
Minor Adjustment (3.2CL M/T)
NOTE: If parking brake shoes or rear discs are replaced, proceed to MAJOR ADJUSTMENT (3.2CL M/T) .
Raise and support rear of vehicle. Pull parking brake lever up one click. Remove rear console mat and cover. Tighten adjusting nut "A" until parking brakes drag slightly when rear wheels are turned. See Fig. 5 .
Release parking brake lever fully, and check that parking brakes do not drag when rear wheels are turned. Readjust if necessary. Ensure parking brakes are fully applied when parking brake lever is pulled up fully. Reinstall rear console cover and mat.
Fig. 5: Turning Adjusting Nut "A" (3.2CL M/T)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Major Adjustment (3.2CL M/T)
Raise and support rear of vehicle. Remove rear console mat and cover. Release parking brake lever, and loosen adjusting nut "A". See Fig. 5 . Remove rear wheels.
Remove access plug "A". See Fig. 6 . Turn brake shoe adjuster "B" with a flat-blade screwdriver "C" until shoes lock, then back of 8 stops. Repeat this adjustment on other side of vehicle.
Check number of clicks required to fully lock parking brake. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T). If parking brake does not lock within specified number of clicks, perform MINOR ADJUSTMENT (3.2CL M/T) . Reinstall rear console cover and mat.
Fig. 6: Adjusting Parking Brake Shoes
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Minor Adjustment (3.2CL A/T & 3.2TL)
Raise and support rear of vehicle. Release parking brake. Tighten adjusting nut "A" until parking brakes drag slightly when rear wheels are turned. See Fig. 7 .
Back off adjusting nut "A" in half-turn increments, and check that parking brakes do not drag when rear wheels are turned. Check for proper adjustment (number of clicks) at specified pedal force. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T).
Fig. 7: Tightening Adjustment Nut "A" (3.2CL A/T & 3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Major Adjustment (3.2CL A/T & 3.2TL)
Raise and support rear of vehicle. Release parking brake. Loosen adjusting nut "A". See Fig. 8 . Remove rear wheels.
Remove access plug "A". See Fig. 6 . Turn brake shoe adjuster "B" with a flat-blade screwdriver "C" until shoes lock, then back of 8-10 stops. Repeat this adjustment on other side of vehicle.
Check number of clicks required to fully lock parking brake. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T). If parking brake does not lock within specified number of clicks, perform MINOR ADJUSTMENT (3.2CL A/T & 3.2TL) . Reinstall rear wheels.
Fig. 8: Loosening Adjustment Nut "A" (3.2CL A/T & 3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE LINING BREAK-IN
NOTE: Perform this procedure only when new parking brake shoes or new rear brake discs have been installed.
3.2CL A/T & 3.2TL
Check parking brake adjustment. See PARKING BRAKE under ADJUSTMENTS.
With parking brake adjusted correctly, park car on firm, level surface.
Release parking brake pedal. Press parking brake pedal one click. Drive vehicle for 1/4 mile at about 31 MPH. Stop vehicle for 5-10 minutes to allow brake discs to cool.
Repeat step 3 , 3 more times.
Check parking brake adjustment. See ADJUSTMENT CHECK (EXCEPT 3.2CL M/T) under PARKING BRAKE.
3.2CL M/T
Check parking brake adjustment. See PARKING BRAKE under ADJUSTMENTS.
With parking brake adjusted correctly, park car on firm, level surface.
Keep parking brake lever release button "A" pushed in with a piece of tape. See Fig. 9 . Attach a spring scale "B" to center of lever grip "C". Have an assistant pull parking brake lever up with 19.8 ft. lbs. (88 N) of force.
Drive vehicle for 1/4 mile at about 31 MPH. Release parking brake lever and stop vehicle for 5-10 minutes to allow brake discs to cool.
Repeat step 4 , 3 more times.
Check parking brake adjustment. See ADJUSTMENT CHECK (3.2CL M/T) under PARKING BRAKE.
Fig. 9: Pulling Parking Brake Lever
Courtesy of AMERICAN HONDA MOTOR CO., INC.
STOPLIGHT SWITCH
NOTE: Stoplight switch may also be referred to as brake pedal position switch.
Locate stoplight switch, above brake pedal. Turn ignition switch to OFF position. Using hand pressure, check brake pedal free play. See BRAKE PEDAL HEIGHT & FREE PLAY . If brake pedal free play is not as specified, go to next step.
Loosen stoplight switch lock nuts. Turn stoplight switch inward until plunger threaded end is touching pedal arm pad. See Fig. 2 . Back off switch 1/4 turn until clearance between threaded end and pedal end is .01" (0.3 mm). Tighten lock nuts. Ensure brakelights go off when pedal is released.
TROUBLE SHOOTING
BRAKE SYSTEM OPERATION & LEAKAGE
See Fig. 10 for view of brake system components and trouble shooting flow charts.
Fig. 10: Trouble Shooting Brake System
Courtesy of AMERICAN HONDA MOTOR CO., INC.
TESTING
BRAKE BOOSTER
Functional Test
With engine stopped, press brake pedal several times to deplete vacuum reservoir, then press pedal hard and hold it for 15 seconds. If pedal sinks, either master cylinder is bypassing internally, or brake system (master cylinder, lines, modulator, proportioning valve, or caliper) is leaking. Start engine with pedal pressed. If pedal sinks slightly, vacuum booster is operating normally. If pedal height does not vary, booster or check valve is faulty. With engine running, press brake pedal lightly. Apply just enough pressure to hold back automatic transmission creep. If brake pedal sinks in 3 minutes more than .4" (10 mm), or more than 1.0" (25 mm), the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to booster.)
Leak Test
Press brake pedal with engine running, then stop engine. If pedal height does not vary while pressed for 30 seconds, the vacuum booster is okay. If the pedal rises, booster is faulty. Turn engine off and wait 30 seconds. Press brake pedal several times using normal pressure. When pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If pedal position does not vary, check booster check valve. See BOOSTER CHECK VALVE TEST .
Booster Check Valve Test
Disconnect brake booster vacuum hose at booster. Check valve is built into hose. See Fig. 11 . Start engine, and let it idle. There should be vacuum available. If no vacuum is available, check valve is not working properly. Replace brake booster vacuum hose and check valve, and retest.
Start engine, and pinch brake booster vacuum hose between check valve and booster. Turn engine off and wait 30 seconds. Press brake pedal several times using normal pressure. When pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If pedal position does not vary, replace brake booster. If pedal position varies, replace brake booster vacuum hose/check valve assembly.
Fig. 11: Locating Brake Booster Vacuum Hose (Typical)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
BRAKE FLUID LEVEL SWITCH
Remove brake fluid reservoir cap. Ensure brake fluid float moves up and down freely. If float does not move freely, replace brake fluid reservoir cap. If float moves freely, check for continuity between brake fluid level switch connector terminals. Continuity should exist with float down. Continuity should not exist with float up. If continuity is not as specified, replace brake fluid reservoir cap.
PARKING BRAKE SWITCH
Remove instrument panel lower cover and knee bolster. Disconnect parking brake switch connector. Check for continuity between switch terminal and ground. Continuity should exist with parking brake applied. Continuity should not exist with parking brake released. If continuity is not as specified, check parking brake switch plate adjustment with parking brake switch. If adjustment is okay, replace parking brake switch.
REMOVAL & INSTALLATION
BRAKE BOOSTER
Removal & Installation
Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from brake booster. See Fig. 13 . Remove fuel feed line bracket. Remove starter cable clamps and windshield wiper intermittent relay bracket. Remove lock pin and joint (clevis) pin. See Fig. 12 . Remove four booster mounting nuts. Pull brake booster forward, then turn it to the right until clevis is clear of bulkhead at cutout. See Fig. 14 . To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Fig. 12: Identifying Pins & Booster Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 13: Identifying Feed Line & Starter Cable Clamps
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 14: Removing Brake Booster
Courtesy of AMERICAN HONDA MOTOR CO., INC.
DISC BRAKE ROTOR
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal (Front & Rear)
Raise and support vehicle. Remove wheels. Remove caliper assembly, and wire aside. Remove disc brake pads. Remove caliper mounting bracket.
NOTE: Manufacturer recommends front rotors be resurfaced using on-vehicle disc brake lathe.
Before removing rotor, inspect rotor runout and rotor surfaces for cracks or damage. Using wheel lug nuts and washers, secure rotor to hub. Measure rotor runout 0.4" (10 mm) from edge of rotor. Refinish rotor if runout exceeds specification. See DISC BRAKE SPECIFICATIONS .
Remove 6-mm rotor retaining screws. Install two 8 x 12 mm bolts into existing holes. To prevent warpage, turn bolts alternately 2 turns at a time until rotor can be removed from hub.
Clean rust from rotor. Inspect rotor surfaces for cracks or grooves. Resurface or replace rotor as necessary.
Installation
To install, reverse removal procedure. Tighten retaining screws and bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system if necessary. See BLEEDING BRAKE SYSTEM . For rear brake disc, perform brake shoe lining break-in procedure. See PARKING BRAKE LINING BREAK-IN under ADJUSTMENTS.
FRONT DISC BRAKE PADS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove front wheels. Remove brake hose bracket from knuckle. Remove lower caliper bolt, and pivot caliper up out of the way.
Remove pads, pad shims, and pad retainers. Measure thickness of brake lining. Minimum brake pad thickness is .06" (1.60 mm). Clean caliper and bracket, and check for cracks or grooves. Check disc rotor for damage and cracks. Repair or replace as necessary. See Fig. 15 .
NOTE: Replace brake pads in axle sets. DO NOT allow grease, brake fluid, or other contaminants to contact lining surface. Inspect, clean, and resurface or replace rotor as necessary.
Installation
Lubricate shim and sliding surfaces with high-temperature silicone grease. Install pad retainers. Apply Molykote(R) M77 (or equivalent) compound to both sides of pad shims and back of pads.
Install inner and outer pad shims. Install brake pads in brackets. Install inner brake pad with pad wear indicator on the inside. Push piston into caliper bore with finger pressure so caliper will fit over pads.
Pivot caliper down and install lower caliper bolt. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Depress brake pedal several times to restore normal brake pedal stroke. If necessary, bleed brakes. See BLEEDING BRAKE SYSTEM .
Fig. 15: Exploded View Of Front Brake Caliper
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER
Removal & Installation
Remove flange nuts "A" and strut brace "B". See Fig. 16 . Disconnect brake fluid level switch connectors, and remove reservoir cap. Remove brake fluid from master cylinder reservoir with a syringe. Disconnect brake lines from master cylinder. To prevent spills, cover hose joints with rags. Remove master cylinder mounting nuts and washers. Remove master cylinder from brake booster. Be careful not to damage brake lines. To install, reverse removal procedure. Replace all rubber parts with new ones whenever, removed. Coat the lip of the new rod seal with seal grease in the master cylinder set. Install the rod seal onto the master cylinder with its grooved side toward the master cylinder. Tighten nuts and brakelines to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Fig. 16: Removing Flange Nuts & Strut Brace
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE CABLE
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Removal & Installation (3.2CL)
Refer to exploded view as needed during this procedure. See Fig. 17 .
Raise and support rear of vehicle. Remove rear wheels.
Do not disconnect ABS sensor connector. Remove ABS sensor harness bracket "A" from rear knuckle. See Fig. 18 . Remove lower damper mounting bolt "B".
Remove parking brake cable "A" from trailing arm "B". See Fig. 19 .
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove rear hubs.
Remove the parking brake shoes. See PARKING BRAKE SHOES . Disconnect the parking brake cable from the parking brake lever.
Remove the 16 mm and 10 mm flange nuts in back of the rear knuckle. See Fig. 20 . Separate the backing plate "A" from the rear knuckle "B".
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 17: Exploded View Of Parking Brake Cable
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 18: Removing ABS Sensor Harness Bracket & Lower Damper Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 19: Removing Parking Brake Cable From Trailing Arm
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 20: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 21: Removing Parking Brake Cable Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Removal & Installation (3.2TL)
Refer to exploded view as needed during this procedure. See Fig. 22 .
Raise and support rear of vehicle. Remove rear wheels.
Remove the cotter pin from the upper ball joint castle nut, and remove the nut. See Fig. 23 . Using Ball Joint Remover (07MAC-SL00200), separate upper ball joint from knuckle.
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove the ABS sensor from the brake backing plate. See Fig. 24 .
Remove the flange nut "A" from the stabilizer link while holding the stabilizer link stud with a hex wrench "B". See Fig. 25 . Remove the damper lower mounting bolt "C", and the stabilizer link mounting bracket "D".
Remove 10 mm control arm flange nut from the rear knuckle. See Fig. 26 .
Remove the leading arm mounting bolt from the rear knuckle. See Fig. 27 .
Remove the backing plate flange nuts. See Fig. 20 .
Remove rear disc brake rotor and hub. See DISC BRAKE ROTOR .
Remove parking brake shoes. See PARKING BRAKE SHOES .
Remove backing plate from rear knuckle. Remove parking brake cable mounting bolt "A" from trailing arm "B". See Fig. 28 .
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Use NEW cotter pin. Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 22: Exploded View Of Parking Brake Cable (3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 23: Removing Upper Ball Joint
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 24: Removing Rear ABS Sensor
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 25: Removing Flange Nut "A"
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 26: Removing Control Arm Flange Nut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 27: Removing Leading Arm Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 28: Removing Parking Brake Cable Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE SHOES
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove rear wheels. Remove rear caliper and disc/drum.
Remove brake shoe upper return springs. Remove hold-down springs and tension pins. Remove upper connecting rod and rod spring. Lower parking brake shoes and remove lower return spring and adjuster. Disconnect parking brake cable from parking brake lever. Remove "U" clip, wave washer, parking brake lever, and pivot pin from brake shoes. See Fig. 29 .
Fig. 29: Exploded View Of Parking Brake Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspection
Check brake linings for cracking, glazing, wear and contamination. Replace brake linings as a set if thickness is less than .04" (1.0 mm). Check inside of disc/drum brake rotor for scoring, grooves and cracks. Replace disc/drum brake rotor if drum inside diameter is more than 6.732" (171 mm).
Installation
Apply Molykote(R) M44 (or equivalent) grease to sliding surface of pivot pin. Install pivot pin into brake shoe. Install parking brake lever and wave washer onto pivot pin, and secure using NEW "U" clip. Connect parking brake cable to parking brake lever. Apply Molykote(R) M44 (or equivalent) grease to brake shoe contact points. See Fig. 30 .
Clean threaded portions of adjuster assembly clevis, and coat with grease. To shorten clevis, turn adjuster bolt. Install adjuster assembly and lower return spring. Connect rod spring to connecting rod with hook pointing downward. Install tension pins and hold-down springs. Install upper return springs.
Install disc and 6-mm screws. Adjust parking brake. Install rear brake caliper. Bleed hydraulic system if necessary. See BLEEDING BRAKE SYSTEM . If new parking brake shoes or new brake discs have been installed, perform brake shoe lining break-in procedure. See PARKING BRAKE LINING BREAK-IN under ADJUSTMENTS.
Fig. 30: Greasing Contact Points Of Parking Brakes
Courtesy of AMERICAN HONDA MOTOR CO., INC.
REAR DISC BRAKE PADS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove wheels. Remove caliper mounting bolts and caliper from caliper bracket. Remove brake pad shims, brake pads and retainers. Measure friction pad thickness. Service limit is .06" (1.6 mm).
Installation
Clean caliper thoroughly. Remove rust and check for grooves or cracks. Install pad retainers in correct positions. Apply Molykote(R) M77 (or equivalent) compound to pad side of pad shims. Install brake pads and shims. See Fig. 31 .
Push in piston so caliper will fit over brake pads. Align cut-out in piston with tab on inner pad. Apply a rubber lubricant to piston boot to keep boot from twisting. Install brake caliper and caliper bracket. Pump brake pedal several times to seat pads. If necessary, bleed brakes. See BLEEDING BRAKE SYSTEM . Depress brake pedal several times to restore normal brake pedal stroke. Adjust parking brake if necessary.
Fig. 31: Exploded View Of Rear Brake Caliper
Courtesy of AMERICAN HONDA MOTOR CO., INC.
OVERHAUL
FRONT & REAR DISC BRAKE CALIPERS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
WARNING: DO NOT put hand in front of piston when using air pressure to remove piston.
CAUTION: Ensure brake fluid does not spill on painted surfaces, as damage to finish will result.
See Fig. 32 and Fig. 33 for exploded views of brake caliper components and procedures.
Fig. 32: Exploded View Of Front Brake Caliper Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 33: Exploded View Of Rear Brake Caliper Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER
Disassembly & Reassembly
DO NOT disassemble master cylinder. Replace master cylinder if defective.
POWER BRAKE BOOSTER
Disassembly & Reassembly
DO NOT disassemble power brake unit. Replace power brake booster if defective.
TORQUE SPECIFICATIONS
For disc brake torque specifications, see DISC BRAKES in ACURA 3.2CL article in SPECIFICATIONS.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Booster
Push Rod Lock Nut 11 (15)
Mounting Nut 10 (13)
Brakeline-To-Flex Hose 11 (15)
Brakeline-To-Master Cylinder
3.2CL
(1) 14 (19)
(2) 11 (15)
Brakeline-To-ABS Modulator Unit 14 (19)
Caliper Mounting Bracket Bolt
Front 80 (108)
Rear 41 (55)
Caliper-To-Bracket Mounting Bolt
Front 36 (49)
Rear 17 (23)
Flex Hose-To-Caliper Banjo Bolt 25.1 (34)
Master Cylinder Mounting Nut 11 (15)
Wheel Lug Nut 80 (108)
INCH Lbs. (N.m)
Brake Bleed Screw 80 (9)
Rotor Retaining Screws 89 (10)
(1) With Traction Control System (TCS).
(2) With Vehicle Stability Assist (VSA)
DISC BRAKE SPECIFICATIONS
For disc brake specifications, see DISC BRAKES in ACURA 3.2CL article in SPECIFICATIONS.
Disc - 3.2CL & 3.2TL
DESCRIPTION & OPERATION
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Avoid spilling brake fluid on car, as it will damage paint. If brake fluid contacts paint, immediately flush with water.
All models are equipped with front and rear disc brakes. A cable operates parking brake at rear wheels. The parking brake uses drum brake shoes mounted inside rear disc brake rotor. See Fig. 1 .
Fig. 1: Locating Brake Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURE
CAUTION: Use only clean DOT 3 brake fluid. Ensure no dirt or other foreign matter contaminates brake fluid. DO NOT mix different brands of brake fluid, as they may not be compatible. Avoid spilling brake fluid on car, as it will damage paint. If brake fluid contacts paint, immediately flush with water.
CAUTION: DO NOT press brake pedal all the way to the floor. Press brake pedal half-way to avoid damage to master cylinder piston seal. Damage to piston seal can cause internal and/or external leaks.
Ensure master cylinder reservoir is full before performing bleeding procedure. Refill reservoir after bleeding each wheel. Have an assistant slowly pump brake pedal several times, then apply steady pressure. Loosen brake bleed screw at each wheel to allow air to escape from system. Tighten bleed screw to specification. See TORQUE SPECIFICATIONS . Repeat procedure until air bubbles no longer appear in fluid.
Bleed brakes in following sequence. See BRAKELINE BLEEDING SEQUENCE table. Ensure master cylinder reservoir is full. Road test vehicle and check brake performance.
BRAKELINE BLEEDING SEQUENCE
Application Sequence
3.2CL & 3.2TL LF, RF, RR, LR
ADJUSTMENTS
BRAKE PEDAL HEIGHT & FREE PLAY
Measure pedal height from right side center of pedal pad to floor panel, with carpet cutout turned up. See BRAKE PEDAL HEIGHT & FREE PLAY table. See Fig. 2 .
To adjust brake pedal height, disconnect stoplight switch. Loosen stoplight switch lock nut and back off switch until it no longer touches brake pedal. Loosen power brake booster push rod lock nut. Rotate push rod to adjust pedal height. Tighten lock nut to specification. See TORQUE SPECIFICATIONS .
Turn ignition switch to OFF position. Adjust stoplight switch. See STOPLIGHT SWITCH . See BRAKE PEDAL HEIGHT & FREE PLAY table.
BRAKE PEDAL HEIGHT & FREE PLAY
Application In. (mm)
Brake Pedal Free Play .04-.20 (1.0-5.0)
Brake Pedal Height (1)
3.2CL 6.63 (168.0)
3.2TL 6.65 (169.0)
(1) With carpet cutout turned up.
Fig. 2: Adjusting Brake Pedal Height & Free Play
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER PUSH ROD CLEARANCE
NOTE: Master cylinder push rod-to-piston clearance must be checked and adjusted before installing master cylinder.
Mount Push Rod Adjustment Gauge (07JAG-SD40100) on master cylinder. Rotate adjuster nut until top of center shaft contacts end of secondary piston without changing piston position. See Fig. 3 .
Remove push rod adjustment gauge from master cylinder, and install on brake booster. Tighten master cylinder nuts to specification. See TORQUE SPECIFICATIONS . Using engine or outside vacuum source, apply a continuous 20 in. Hg vacuum to brake booster.
Using a feeler gauge, ensure clearance between gauge body and adjusting nut is .02" (0.4 mm). See Fig. 4 .
Loosen star lock nut and rotate adjuster nut in or out to adjust clearance. Hold push rod, and rotate adjuster in or out for specified clearance. DO NOT pull push rod out of brake booster. Tighten star lock nut securely.
Fig. 3: Setting Push Rod Adjustment Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 4: Measuring Push Rod Clearance
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE
Adjustment Check (3.2CL M/T)
Pull parking brake lever with 66 lbs. (294 N) of force to fully apply parking brake. Parking brake lever should be locked with 6-10 clicks.
Adjustment Check (Except 3.2CL M/T)
Press parking brake pedal with 66 lbs. (294 N) of force. Parking brake pedal should lock with specified number of clicks. See PARKING BRAKE ADJUSTMENT CHECK table.
PARKING BRAKE ADJUSTMENT CHECK
Application No. Of Clicks For Parking Brake Lock
3.2CL
A/T (1) 2-4
M/T (2) 6-10
3.2TL (1) 2-4
(1) Press parking brake pedal with 66 lbs. (294 N) of force to fully apply parking brake.
(2) Pull parking brake pedal with 66 lbs. (194 N) of force to fully apply parking brake.
Minor Adjustment (3.2CL M/T)
NOTE: If parking brake shoes or rear discs are replaced, proceed to MAJOR ADJUSTMENT (3.2CL M/T) .
Raise and support rear of vehicle. Pull parking brake lever up one click. Remove rear console mat and cover. Tighten adjusting nut "A" until parking brakes drag slightly when rear wheels are turned. See Fig. 5 .
Release parking brake lever fully, and check that parking brakes do not drag when rear wheels are turned. Readjust if necessary. Ensure parking brakes are fully applied when parking brake lever is pulled up fully. Reinstall rear console cover and mat.
Fig. 5: Turning Adjusting Nut "A" (3.2CL M/T)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Major Adjustment (3.2CL M/T)
Raise and support rear of vehicle. Remove rear console mat and cover. Release parking brake lever, and loosen adjusting nut "A". See Fig. 5 . Remove rear wheels.
Remove access plug "A". See Fig. 6 . Turn brake shoe adjuster "B" with a flat-blade screwdriver "C" until shoes lock, then back of 8 stops. Repeat this adjustment on other side of vehicle.
Check number of clicks required to fully lock parking brake. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T). If parking brake does not lock within specified number of clicks, perform MINOR ADJUSTMENT (3.2CL M/T) . Reinstall rear console cover and mat.
Fig. 6: Adjusting Parking Brake Shoes
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Minor Adjustment (3.2CL A/T & 3.2TL)
Raise and support rear of vehicle. Release parking brake. Tighten adjusting nut "A" until parking brakes drag slightly when rear wheels are turned. See Fig. 7 .
Back off adjusting nut "A" in half-turn increments, and check that parking brakes do not drag when rear wheels are turned. Check for proper adjustment (number of clicks) at specified pedal force. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T).
Fig. 7: Tightening Adjustment Nut "A" (3.2CL A/T & 3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Major Adjustment (3.2CL A/T & 3.2TL)
Raise and support rear of vehicle. Release parking brake. Loosen adjusting nut "A". See Fig. 8 . Remove rear wheels.
Remove access plug "A". See Fig. 6 . Turn brake shoe adjuster "B" with a flat-blade screwdriver "C" until shoes lock, then back of 8-10 stops. Repeat this adjustment on other side of vehicle.
Check number of clicks required to fully lock parking brake. See PARKING BRAKE ADJUSTMENT CHECK table under CHECK (EXCEPT 3.2CL M/T). If parking brake does not lock within specified number of clicks, perform MINOR ADJUSTMENT (3.2CL A/T & 3.2TL) . Reinstall rear wheels.
Fig. 8: Loosening Adjustment Nut "A" (3.2CL A/T & 3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE LINING BREAK-IN
NOTE: Perform this procedure only when new parking brake shoes or new rear brake discs have been installed.
3.2CL A/T & 3.2TL
Check parking brake adjustment. See PARKING BRAKE under ADJUSTMENTS.
With parking brake adjusted correctly, park car on firm, level surface.
Release parking brake pedal. Press parking brake pedal one click. Drive vehicle for 1/4 mile at about 31 MPH. Stop vehicle for 5-10 minutes to allow brake discs to cool.
Repeat step 3 , 3 more times.
Check parking brake adjustment. See ADJUSTMENT CHECK (EXCEPT 3.2CL M/T) under PARKING BRAKE.
3.2CL M/T
Check parking brake adjustment. See PARKING BRAKE under ADJUSTMENTS.
With parking brake adjusted correctly, park car on firm, level surface.
Keep parking brake lever release button "A" pushed in with a piece of tape. See Fig. 9 . Attach a spring scale "B" to center of lever grip "C". Have an assistant pull parking brake lever up with 19.8 ft. lbs. (88 N) of force.
Drive vehicle for 1/4 mile at about 31 MPH. Release parking brake lever and stop vehicle for 5-10 minutes to allow brake discs to cool.
Repeat step 4 , 3 more times.
Check parking brake adjustment. See ADJUSTMENT CHECK (3.2CL M/T) under PARKING BRAKE.
Fig. 9: Pulling Parking Brake Lever
Courtesy of AMERICAN HONDA MOTOR CO., INC.
STOPLIGHT SWITCH
NOTE: Stoplight switch may also be referred to as brake pedal position switch.
Locate stoplight switch, above brake pedal. Turn ignition switch to OFF position. Using hand pressure, check brake pedal free play. See BRAKE PEDAL HEIGHT & FREE PLAY . If brake pedal free play is not as specified, go to next step.
Loosen stoplight switch lock nuts. Turn stoplight switch inward until plunger threaded end is touching pedal arm pad. See Fig. 2 . Back off switch 1/4 turn until clearance between threaded end and pedal end is .01" (0.3 mm). Tighten lock nuts. Ensure brakelights go off when pedal is released.
TROUBLE SHOOTING
BRAKE SYSTEM OPERATION & LEAKAGE
See Fig. 10 for view of brake system components and trouble shooting flow charts.
Fig. 10: Trouble Shooting Brake System
Courtesy of AMERICAN HONDA MOTOR CO., INC.
TESTING
BRAKE BOOSTER
Functional Test
With engine stopped, press brake pedal several times to deplete vacuum reservoir, then press pedal hard and hold it for 15 seconds. If pedal sinks, either master cylinder is bypassing internally, or brake system (master cylinder, lines, modulator, proportioning valve, or caliper) is leaking. Start engine with pedal pressed. If pedal sinks slightly, vacuum booster is operating normally. If pedal height does not vary, booster or check valve is faulty. With engine running, press brake pedal lightly. Apply just enough pressure to hold back automatic transmission creep. If brake pedal sinks in 3 minutes more than .4" (10 mm), or more than 1.0" (25 mm), the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to booster.)
Leak Test
Press brake pedal with engine running, then stop engine. If pedal height does not vary while pressed for 30 seconds, the vacuum booster is okay. If the pedal rises, booster is faulty. Turn engine off and wait 30 seconds. Press brake pedal several times using normal pressure. When pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If pedal position does not vary, check booster check valve. See BOOSTER CHECK VALVE TEST .
Booster Check Valve Test
Disconnect brake booster vacuum hose at booster. Check valve is built into hose. See Fig. 11 . Start engine, and let it idle. There should be vacuum available. If no vacuum is available, check valve is not working properly. Replace brake booster vacuum hose and check valve, and retest.
Start engine, and pinch brake booster vacuum hose between check valve and booster. Turn engine off and wait 30 seconds. Press brake pedal several times using normal pressure. When pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If pedal position does not vary, replace brake booster. If pedal position varies, replace brake booster vacuum hose/check valve assembly.
Fig. 11: Locating Brake Booster Vacuum Hose (Typical)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
BRAKE FLUID LEVEL SWITCH
Remove brake fluid reservoir cap. Ensure brake fluid float moves up and down freely. If float does not move freely, replace brake fluid reservoir cap. If float moves freely, check for continuity between brake fluid level switch connector terminals. Continuity should exist with float down. Continuity should not exist with float up. If continuity is not as specified, replace brake fluid reservoir cap.
PARKING BRAKE SWITCH
Remove instrument panel lower cover and knee bolster. Disconnect parking brake switch connector. Check for continuity between switch terminal and ground. Continuity should exist with parking brake applied. Continuity should not exist with parking brake released. If continuity is not as specified, check parking brake switch plate adjustment with parking brake switch. If adjustment is okay, replace parking brake switch.
REMOVAL & INSTALLATION
BRAKE BOOSTER
Removal & Installation
Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from brake booster. See Fig. 13 . Remove fuel feed line bracket. Remove starter cable clamps and windshield wiper intermittent relay bracket. Remove lock pin and joint (clevis) pin. See Fig. 12 . Remove four booster mounting nuts. Pull brake booster forward, then turn it to the right until clevis is clear of bulkhead at cutout. See Fig. 14 . To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Fig. 12: Identifying Pins & Booster Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 13: Identifying Feed Line & Starter Cable Clamps
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 14: Removing Brake Booster
Courtesy of AMERICAN HONDA MOTOR CO., INC.
DISC BRAKE ROTOR
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal (Front & Rear)
Raise and support vehicle. Remove wheels. Remove caliper assembly, and wire aside. Remove disc brake pads. Remove caliper mounting bracket.
NOTE: Manufacturer recommends front rotors be resurfaced using on-vehicle disc brake lathe.
Before removing rotor, inspect rotor runout and rotor surfaces for cracks or damage. Using wheel lug nuts and washers, secure rotor to hub. Measure rotor runout 0.4" (10 mm) from edge of rotor. Refinish rotor if runout exceeds specification. See DISC BRAKE SPECIFICATIONS .
Remove 6-mm rotor retaining screws. Install two 8 x 12 mm bolts into existing holes. To prevent warpage, turn bolts alternately 2 turns at a time until rotor can be removed from hub.
Clean rust from rotor. Inspect rotor surfaces for cracks or grooves. Resurface or replace rotor as necessary.
Installation
To install, reverse removal procedure. Tighten retaining screws and bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system if necessary. See BLEEDING BRAKE SYSTEM . For rear brake disc, perform brake shoe lining break-in procedure. See PARKING BRAKE LINING BREAK-IN under ADJUSTMENTS.
FRONT DISC BRAKE PADS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove front wheels. Remove brake hose bracket from knuckle. Remove lower caliper bolt, and pivot caliper up out of the way.
Remove pads, pad shims, and pad retainers. Measure thickness of brake lining. Minimum brake pad thickness is .06" (1.60 mm). Clean caliper and bracket, and check for cracks or grooves. Check disc rotor for damage and cracks. Repair or replace as necessary. See Fig. 15 .
NOTE: Replace brake pads in axle sets. DO NOT allow grease, brake fluid, or other contaminants to contact lining surface. Inspect, clean, and resurface or replace rotor as necessary.
Installation
Lubricate shim and sliding surfaces with high-temperature silicone grease. Install pad retainers. Apply Molykote(R) M77 (or equivalent) compound to both sides of pad shims and back of pads.
Install inner and outer pad shims. Install brake pads in brackets. Install inner brake pad with pad wear indicator on the inside. Push piston into caliper bore with finger pressure so caliper will fit over pads.
Pivot caliper down and install lower caliper bolt. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Depress brake pedal several times to restore normal brake pedal stroke. If necessary, bleed brakes. See BLEEDING BRAKE SYSTEM .
Fig. 15: Exploded View Of Front Brake Caliper
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER
Removal & Installation
Remove flange nuts "A" and strut brace "B". See Fig. 16 . Disconnect brake fluid level switch connectors, and remove reservoir cap. Remove brake fluid from master cylinder reservoir with a syringe. Disconnect brake lines from master cylinder. To prevent spills, cover hose joints with rags. Remove master cylinder mounting nuts and washers. Remove master cylinder from brake booster. Be careful not to damage brake lines. To install, reverse removal procedure. Replace all rubber parts with new ones whenever, removed. Coat the lip of the new rod seal with seal grease in the master cylinder set. Install the rod seal onto the master cylinder with its grooved side toward the master cylinder. Tighten nuts and brakelines to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM .
Fig. 16: Removing Flange Nuts & Strut Brace
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE CABLE
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Removal & Installation (3.2CL)
Refer to exploded view as needed during this procedure. See Fig. 17 .
Raise and support rear of vehicle. Remove rear wheels.
Do not disconnect ABS sensor connector. Remove ABS sensor harness bracket "A" from rear knuckle. See Fig. 18 . Remove lower damper mounting bolt "B".
Remove parking brake cable "A" from trailing arm "B". See Fig. 19 .
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove rear hubs.
Remove the parking brake shoes. See PARKING BRAKE SHOES . Disconnect the parking brake cable from the parking brake lever.
Remove the 16 mm and 10 mm flange nuts in back of the rear knuckle. See Fig. 20 . Separate the backing plate "A" from the rear knuckle "B".
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 17: Exploded View Of Parking Brake Cable
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 18: Removing ABS Sensor Harness Bracket & Lower Damper Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 19: Removing Parking Brake Cable From Trailing Arm
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 20: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 21: Removing Parking Brake Cable Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Removal & Installation (3.2TL)
Refer to exploded view as needed during this procedure. See Fig. 22 .
Raise and support rear of vehicle. Remove rear wheels.
Remove the cotter pin from the upper ball joint castle nut, and remove the nut. See Fig. 23 . Using Ball Joint Remover (07MAC-SL00200), separate upper ball joint from knuckle.
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove the ABS sensor from the brake backing plate. See Fig. 24 .
Remove the flange nut "A" from the stabilizer link while holding the stabilizer link stud with a hex wrench "B". See Fig. 25 . Remove the damper lower mounting bolt "C", and the stabilizer link mounting bracket "D".
Remove 10 mm control arm flange nut from the rear knuckle. See Fig. 26 .
Remove the leading arm mounting bolt from the rear knuckle. See Fig. 27 .
Remove the backing plate flange nuts. See Fig. 20 .
Remove rear disc brake rotor and hub. See DISC BRAKE ROTOR .
Remove parking brake shoes. See PARKING BRAKE SHOES .
Remove backing plate from rear knuckle. Remove parking brake cable mounting bolt "A" from trailing arm "B". See Fig. 28 .
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Use NEW cotter pin. Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 22: Exploded View Of Parking Brake Cable (3.2TL)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 23: Removing Upper Ball Joint
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 24: Removing Rear ABS Sensor
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 25: Removing Flange Nut "A"
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 26: Removing Control Arm Flange Nut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 27: Removing Leading Arm Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 28: Removing Parking Brake Cable Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE SHOES
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove rear wheels. Remove rear caliper and disc/drum.
Remove brake shoe upper return springs. Remove hold-down springs and tension pins. Remove upper connecting rod and rod spring. Lower parking brake shoes and remove lower return spring and adjuster. Disconnect parking brake cable from parking brake lever. Remove "U" clip, wave washer, parking brake lever, and pivot pin from brake shoes. See Fig. 29 .
Fig. 29: Exploded View Of Parking Brake Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Inspection
Check brake linings for cracking, glazing, wear and contamination. Replace brake linings as a set if thickness is less than .04" (1.0 mm). Check inside of disc/drum brake rotor for scoring, grooves and cracks. Replace disc/drum brake rotor if drum inside diameter is more than 6.732" (171 mm).
Installation
Apply Molykote(R) M44 (or equivalent) grease to sliding surface of pivot pin. Install pivot pin into brake shoe. Install parking brake lever and wave washer onto pivot pin, and secure using NEW "U" clip. Connect parking brake cable to parking brake lever. Apply Molykote(R) M44 (or equivalent) grease to brake shoe contact points. See Fig. 30 .
Clean threaded portions of adjuster assembly clevis, and coat with grease. To shorten clevis, turn adjuster bolt. Install adjuster assembly and lower return spring. Connect rod spring to connecting rod with hook pointing downward. Install tension pins and hold-down springs. Install upper return springs.
Install disc and 6-mm screws. Adjust parking brake. Install rear brake caliper. Bleed hydraulic system if necessary. See BLEEDING BRAKE SYSTEM . If new parking brake shoes or new brake discs have been installed, perform brake shoe lining break-in procedure. See PARKING BRAKE LINING BREAK-IN under ADJUSTMENTS.
Fig. 30: Greasing Contact Points Of Parking Brakes
Courtesy of AMERICAN HONDA MOTOR CO., INC.
REAR DISC BRAKE PADS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
Removal
Raise and support vehicle. Remove wheels. Remove caliper mounting bolts and caliper from caliper bracket. Remove brake pad shims, brake pads and retainers. Measure friction pad thickness. Service limit is .06" (1.6 mm).
Installation
Clean caliper thoroughly. Remove rust and check for grooves or cracks. Install pad retainers in correct positions. Apply Molykote(R) M77 (or equivalent) compound to pad side of pad shims. Install brake pads and shims. See Fig. 31 .
Push in piston so caliper will fit over brake pads. Align cut-out in piston with tab on inner pad. Apply a rubber lubricant to piston boot to keep boot from twisting. Install brake caliper and caliper bracket. Pump brake pedal several times to seat pads. If necessary, bleed brakes. See BLEEDING BRAKE SYSTEM . Depress brake pedal several times to restore normal brake pedal stroke. Adjust parking brake if necessary.
Fig. 31: Exploded View Of Rear Brake Caliper
Courtesy of AMERICAN HONDA MOTOR CO., INC.
OVERHAUL
FRONT & REAR DISC BRAKE CALIPERS
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
WARNING: DO NOT put hand in front of piston when using air pressure to remove piston.
CAUTION: Ensure brake fluid does not spill on painted surfaces, as damage to finish will result.
See Fig. 32 and Fig. 33 for exploded views of brake caliper components and procedures.
Fig. 32: Exploded View Of Front Brake Caliper Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 33: Exploded View Of Rear Brake Caliper Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.
MASTER CYLINDER
Disassembly & Reassembly
DO NOT disassemble master cylinder. Replace master cylinder if defective.
POWER BRAKE BOOSTER
Disassembly & Reassembly
DO NOT disassemble power brake unit. Replace power brake booster if defective.
TORQUE SPECIFICATIONS
For disc brake torque specifications, see DISC BRAKES in ACURA 3.2CL article in SPECIFICATIONS.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Brake Booster
Push Rod Lock Nut 11 (15)
Mounting Nut 10 (13)
Brakeline-To-Flex Hose 11 (15)
Brakeline-To-Master Cylinder
3.2CL
(1) 14 (19)
(2) 11 (15)
Brakeline-To-ABS Modulator Unit 14 (19)
Caliper Mounting Bracket Bolt
Front 80 (108)
Rear 41 (55)
Caliper-To-Bracket Mounting Bolt
Front 36 (49)
Rear 17 (23)
Flex Hose-To-Caliper Banjo Bolt 25.1 (34)
Master Cylinder Mounting Nut 11 (15)
Wheel Lug Nut 80 (108)
INCH Lbs. (N.m)
Brake Bleed Screw 80 (9)
Rotor Retaining Screws 89 (10)
(1) With Traction Control System (TCS).
(2) With Vehicle Stability Assist (VSA)
DISC BRAKE SPECIFICATIONS
For disc brake specifications, see DISC BRAKES in ACURA 3.2CL article in SPECIFICATIONS.
1st Gear
Joined: Dec 2006
Posts: 1
Likes: 0
Need photos for instructions posted below reguarding replacing the parking brake cable. Thanks.
PARKING BRAKE CABLE
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Removal & Installation (3.2CL)
Refer to exploded view as needed during this procedure. See Fig. 17 .
Raise and support rear of vehicle. Remove rear wheels.
Do not disconnect ABS sensor connector. Remove ABS sensor harness bracket "A" from rear knuckle. See Fig. 18 . Remove lower damper mounting bolt "B".
Remove parking brake cable "A" from trailing arm "B". See Fig. 19 .
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove rear hubs.
Remove the parking brake shoes. See PARKING BRAKE SHOES . Disconnect the parking brake cable from the parking brake lever.
Remove the 16 mm and 10 mm flange nuts in back of the rear knuckle. See Fig. 20 . Separate the backing plate "A" from the rear knuckle "B".
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 17: Exploded View Of Parking Brake Cable
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 18: Removing ABS Sensor Harness Bracket & Lower Damper Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 19: Removing Parking Brake Cable From Trailing Arm
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 20: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 21: Removing Parking Brake Cable Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
PARKING BRAKE CABLE
WARNING: DO NOT use air pressure or a dry brush to clean brake assemblies. Avoid breathing brake dust. Use OSHA-approved vacuum cleaner for cleaning and collecting dust. Avoid contaminating brake pads and discs with brake fluid or grease.
CAUTION: Parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Removal & Installation (3.2CL)
Refer to exploded view as needed during this procedure. See Fig. 17 .
Raise and support rear of vehicle. Remove rear wheels.
Do not disconnect ABS sensor connector. Remove ABS sensor harness bracket "A" from rear knuckle. See Fig. 18 . Remove lower damper mounting bolt "B".
Remove parking brake cable "A" from trailing arm "B". See Fig. 19 .
Remove rear brake rotors. See DISC BRAKE ROTOR . Remove rear hubs.
Remove the parking brake shoes. See PARKING BRAKE SHOES . Disconnect the parking brake cable from the parking brake lever.
Remove the 16 mm and 10 mm flange nuts in back of the rear knuckle. See Fig. 20 . Separate the backing plate "A" from the rear knuckle "B".
Remove the parking brake cable mounting bolts from the backing plate "A", and remove the cable "B". See Fig. 21 .
To install, reverse removal procedure. Tighten components to specification. See TORQUE SPECIFICATIONS . Before installing the wheel, clean the mating surfaces on the brake disc and inside of the wheel. Adjust the parking brake. See PARKING BRAKE under adjustments. Check rear wheel alignment, and adjust it if necessary.
Fig. 17: Exploded View Of Parking Brake Cable
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 18: Removing ABS Sensor Harness Bracket & Lower Damper Mounting Bolt
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 19: Removing Parking Brake Cable From Trailing Arm
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 20: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 21: Removing Parking Brake Cable Mounting Bolts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Got DEP???
Joined: Feb 2006
Posts: 664
Likes: 0
From: Lowell, MA
We got someone who can search and it's their first post!
Good to go Tom! Welcome to the board and I hope someone could post the pictures that you need. Myself, I don't have a Helms or I would do it for you. Sorry.
If you didn't know, you can order one here > http://www.helminc.com/helm/product2...A3HVE053VP3NRC
I'm not sure of your model/year but you can change that on the left of the page. Also, it's the service manual that you want, not the owners manual...
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