Honda S2000 Brake System: inspection, troubleshooting, removal, installation and more
06-21-2009, 09:11 PM
#1
Honda-Tech Member
Thread Starter
Join Date: Jun 2004
Location: St. Paul, MN, U.S. of A
Posts: 1,072
Likes: 0
Received 0 Likes
on
0 Posts
Honda S2000 Brake System: inspection, troubleshooting, removal, installation and more
To see the original article with images check it out here: Honda S2000 Brake System: inspection, troubleshooting, removal, installation and more. Garage411.com
WARNING: 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.
The Honda S2000 uses front disc brakes. Rear brakes are disc type. Parking brake cable mechanism applies rear brakes. Parking brake on rear disc brakes are integral with caliper.
BLEEDING BRAKE SYSTEM
Do not reuse drained fluid. Always use Honda Genuine DOT 3 Brake Fluid from an unopened can. Ensure no dirt or other materials enter brake fluid. Do not spill brake fluid on vehicle, it may damage paint; if some does spill, wash off immediately with water. The reservoir on master cylinder must be at the MAX (upper) level mark at start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.
Raise and support vehicle. Fill master cylinder to maximum using only genuine Honda DOT 3 brake fluid. Have someone slowly pump brake pedal several times, then apply steady pressure. Loosen left-front brake bleed screw to allow air to escape from system, then tighten bleed screw securely. Repeat procedure for each wheel in sequence. Sequence is FL, FR, RR and RL. Fill master cylinder to maximum level line.
BRAKE PEDAL HEIGHT AND FREE PLAY
1. Disconnect brake pedal position switch connector. Loosen brake pedal position switch lock nut and back off switch until it no longer touches brake pedal. Lift up carpet and measure pedal height at insulator cutout, from middle of right side center (middle of left side center).
2. Loosen pushrod lock nut, and screw pushrod in or out with pliers until correct pedal height is obtained. Tighten lock nut firmly. Do not adjust the pedal height with pushrod pressed.
3. Screw in brake pedal position switch until its plunger is fully pressed (threaded end touching pad on pedal arm). Back off switch to make .01" (.3 mm) of clearance between threaded end and pad. Tighten lock nut firmly. Connect brake pedal position switch connector. Make sure brake lights go off when pedal is released. Check brake pedal free play: 7.04 inches (179 mm).
[b]When brake pedal is released, the brake pedal position switch is normally open and the idle stop switch is normally closed.[b]
Free Play
With engine off, check brake pedal free play by pushing pedal by hand. If pedal free play is out of specification, adjust brake switch. See figure. If pedal free play is insufficient, it may result in brake drag. Make sure brake lights go off when pedal is released.
* Brake switch specification: .04-.20 Inches (1-5 mm)
REMOVAL AND INSTALLATION
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
1. 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.
2. 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.
3. 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.
4. 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.
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)
To see the original article with images check it out here: Honda S2000 Brake System: inspection, troubleshooting, removal, installation and more. Garage411.com
WARNING: 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.
The Honda S2000 uses front disc brakes. Rear brakes are disc type. Parking brake cable mechanism applies rear brakes. Parking brake on rear disc brakes are integral with caliper.
BLEEDING BRAKE SYSTEM
Do not reuse drained fluid. Always use Honda Genuine DOT 3 Brake Fluid from an unopened can. Ensure no dirt or other materials enter brake fluid. Do not spill brake fluid on vehicle, it may damage paint; if some does spill, wash off immediately with water. The reservoir on master cylinder must be at the MAX (upper) level mark at start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.
Raise and support vehicle. Fill master cylinder to maximum using only genuine Honda DOT 3 brake fluid. Have someone slowly pump brake pedal several times, then apply steady pressure. Loosen left-front brake bleed screw to allow air to escape from system, then tighten bleed screw securely. Repeat procedure for each wheel in sequence. Sequence is FL, FR, RR and RL. Fill master cylinder to maximum level line.
BRAKE PEDAL HEIGHT AND FREE PLAY
1. Disconnect brake pedal position switch connector. Loosen brake pedal position switch lock nut and back off switch until it no longer touches brake pedal. Lift up carpet and measure pedal height at insulator cutout, from middle of right side center (middle of left side center).
2. Loosen pushrod lock nut, and screw pushrod in or out with pliers until correct pedal height is obtained. Tighten lock nut firmly. Do not adjust the pedal height with pushrod pressed.
3. Screw in brake pedal position switch until its plunger is fully pressed (threaded end touching pad on pedal arm). Back off switch to make .01" (.3 mm) of clearance between threaded end and pad. Tighten lock nut firmly. Connect brake pedal position switch connector. Make sure brake lights go off when pedal is released. Check brake pedal free play: 7.04 inches (179 mm).
[b]When brake pedal is released, the brake pedal position switch is normally open and the idle stop switch is normally closed.[b]
Free Play
With engine off, check brake pedal free play by pushing pedal by hand. If pedal free play is out of specification, adjust brake switch. See figure. If pedal free play is insufficient, it may result in brake drag. Make sure brake lights go off when pedal is released.
* Brake switch specification: .04-.20 Inches (1-5 mm)
REMOVAL AND INSTALLATION
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
1. 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.
2. 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.
3. 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.
4. 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.
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)
To see the original article with images check it out here: Honda S2000 Brake System: inspection, troubleshooting, removal, installation and more. Garage411.com
Last edited by Master23; 07-01-2009 at 06:10 PM.
Thread
Thread Starter
Forum
Replies
Last Post
Floren
Honda Civic (2006 - 2015)
2
06-25-2018 07:18 PM
Jaydeep
Honda Civic / Del Sol (1992 - 2000)
6
06-25-2012 09:25 PM
Master23
Suspension & Brakes
0
06-21-2009 11:33 PM
hermtm2
Honda Civic / Del Sol (1992 - 2000)
3
05-08-2009 10:33 AM
