Removing and installing brake components applies to Honda S2000 1999-2003 models.
Take care not to breath in brake dust. Brake dust is filled with asbestos which causes mesothelioma cancer and or tumor. Mesothelioma destroys tissue and organs and have the potential to spread to other parts of the body. Always clean brake parts with a certified brake parts cleaner before working on the brake system. This will reduce the amount of exposure to asbestos.
FRONT BRAKE PADS REMOVAL, INSPECTION AND INSTALLATION
- Raise and support vehicle. Remove wheels. Remove brake hose mounting bolts from knuckle as necessary. Use wrench to hold sub pin to prevent twisting boot. Remove lower flange bolt and pivot caliper up out of way. Check hoses and pin boots for damage and deterioration. Remove pad shims, pad retainers, and pads. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate thickness.
- If brake pad thickness is less than service limit, replace front pads as a set. Clean caliper thoroughly; remove any rust, and check for grooves and cracks. Check brake disc for damage and cracks. Install pad retainers. Apply Dow Corning Molykote M77 grease to both sides of pad shims and back of pads. Wipe excess grease off shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off discs and pads.
- Install brake pads and pad shims correctly. Install pad with wear indicators on inside. If you are reusing pads, always reinstall pads in their original positions to prevent a momentary loss of braking efficiency. Push in piston so caliper will fit over pads. Make sure piston boot is in position to prevent damaging it when pivoting caliper down.
- Pivot caliper down into position. Being careful not to damage pin boot, install flange bolt and torque to specifications. Install brake hose onto knuckle, if removed. Press brake pedal several times to make sure brakes work, then test-drive. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Engagement of brake may require a greater pedal stroke immediately after brake pads have been replaced as a set. Several applications of brake pedal will restore normal pedal stroke.
FRONT AND REAR BRAKE DISC REMOVAL AND INSTALLATION
- Raise and support vehicle. Remove wheels. Remove caliper assembly, and suspend it using wire. Install washers and nuts to hold rotor to hub. Attach dial indicator to caliper mount .40″ (10.0 mm) from disc outer edge. Check disc runout before removal.
- Detach and remove two 6-mm disc retaining screws. Install two 8 x 1.25 x 12-mm bolts in existing holes. To prevent warpage, alternately turn bolts 2 turns at a time until disc can be removed from hub.
- Clean disc of all rust, and inspect disc surfaces for cracks and grooves. Replace disc as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system, if necessary.
MASTER CYLINDER REMOVAL AND INSTALLATION
See figure for exploded view of master cylinder components and removal procedures. Check pushrod clearance before installing master cylinder, and adjust if necessary.
REAR DISC BRAKE PADS REMOVAL AND INSTALLATION
Raise and support vehicle. Remove wheels. Remove flange bolts while holding pins with a wrench being careful not to damage pin boot, and remove caliper. Support caliper so it does not hang on brake hose. Check hose and pin boots for damage and deterioration. Remove pad shims, pads, and pad retainers. Clean caliper thoroughly; remove any rust and check for grooves and cracks. Check thickness of brake pads.
Apply Dow Corning Molykote M77 grease to pad side of shims. Wipe off excess. Install brake pads and shims correctly. Install pad with wear indicator on inside. If you are reusing pads, reinstall in original position. Rotate piston clockwise into cylinder, then align cutout in piston with tab on inner pad by turning piston back. See figure Lubricate boot with rubber grease to avoid twisting piston boot. If piston boot is twisted, back it out so it is positioned properly. To complete installation, reverse removal procedures.
Engagement of brake may require a greater pedal stroke immediately after brake pads have been replaced as a set. Several applications of brake pedal will restore normal pedal stroke. Check parking brake adjustment. Check for leaks at hose line joints or connections, and retighten.
PARKING BRAKE CABLE REMOVAL AND INSTALLATION
The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.
Remove caliper shield. Release parking brake fully. Remove brake clip from parking brake cable at caliper. Disconnect parking brake cable from parking brake arm at caliper. Refer to illustration as needed for procedure. See figure.
TORQUE SPECIFICATIONS Ft. Lbs. (N.m)
- Brake Booster Push Rod Lock Nut: 11 (15)
- Brake Booster Push Rod Star Lock Nut: 16 (22)
- Brake Hose Banjo Bolt: 25 (34)
- Brakeline-To-ABS Unit: 11 (15)
- Brakeline-To-Brake Hose: 11 (15)
- Brakeline-To-Master Cylinder: 11 (15)
- Brakeline-To-Proportioning Control Valve: 11 (15)
- Brake Pedal Pushrod Lock Nut: 11 (15)
- Caliper Bolt: 16 (22)
- Caliper Mounting Bracket Bolt: 41 (55)
- Master Cylinder Mounting Nut: 11 (15)
- Parking Brake Arm Nut: 20 (27)
- Parking Brake Cable Bolt: 16 (22)
- Parking Brake Lever Bolt: 16 (22)
- Wheel Lug Nuts: 80 (108)
TORQUE SPECIFICATIONS INCH Lbs. (N.m)
- Brake Booster Mounting Nuts 101 INCH Lbs. (13 N.m)
- Brake Hose Mounting Bolts 87 INCH Lbs. (9.8 N.m)
- Bleeder Screw 80 INCH Lbs. (9 N.m)
- Caliper Shield Bolt (Rear) 89 INCH Lbs. (10 N.m)
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