Honda Civic 1992-1995 Disc and Drum Brakes: push rods, pads, calipers and more
06-21-2009, 11:33 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 Civic 1992-1995 Disc and Drum Brakes: push rods, pads, calipers and more
To see the original article with images check it out here: Honda Civic 1992-1995 Disc and Drum Brakes: push rods, pads, calipers 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.
All models use front disc brakes. Rear brakes may be either disc type or self-adjusting drum type. Parking brake cable mechanism applies rear brakes.
BRAKE SYSTEM BLEEDING PROCEDURES
Raise and support vehicle. Fill master cylinder to maximum. Check fluid level after bleeding each wheel position. Bleed brakes in following sequence: RR, LF, LR and RF.
BRAKE PEDAL HEIGHT ADJUSTMENT
Loosen brakelight switch lock nut, and back off switch until it no longer touches brake pedal. Loosen brake pedal push rod lock nut, and screw push rod in or out until correct pedal height is obtained.
* Civic and Civic del Sol AUTOMATIC: 6.5 inches (165 mm)
* Civic and Civic del Sol MANUAL: 6.3 inches (160mm)
BRAKE WARNING LIGHT
Brake warning light indicates parking brake is engaged and/or brake fluid level is low. To adjust parking brake light operation, turn ignition on. Bend switch plate down until light comes on when parking brake lever is pulled one notch and goes out when lever is released.
MASTER CYLINDER PUSH ROD
Check and adjust master cylinder push rod-to-piston clearance before installing master cylinder.
1. Install Push Rod Adjustment Gauge (07JAG-SD40100) so gauge rod makes light contact with secondary piston of master cylinder.
Ensure gasket is in position when adjusting rod clearance.
2. Remove push rod adjustment gauge from master cylinder, and install gauge onto brake booster. See figure. Tighten mounting nuts to specification. Using engine or outside vacuum source, apply at least 10 in. Hg vacuum to brake booster. Check clearance using feeler gauge
* Civic and Civic del Sol: 0-.016" (0-.40 mm)
PARKING BRAKE
Before adjusting parking brake, loosen equalizer adjusting nut. Start engine, and depress brake pedal several times to set self-adjusting brakes before adjusting parking brake.
1. With rear brakes adjusted, raise and support rear of vehicle. Loosen equalizer nut, and pull parking brake lever up one notch. Tighten equalizer adjusting nut until rear wheels drag slightly.
2. Release parking brake lever. Rear wheels should rotate freely. Rear wheels should lock when parking brake lever is pulled up 6-10 clicks.
REAR DRUM BRAKE SHOES
Rear brake shoes will self-adjust through brake pedal action. No in-service adjustment is required.
STOPLIGHT SWITCH
1. Stoplight switch is located under dash, above brake pedal. To adjust, loosen lock nuts and turn switch until plunger is fully depressed (threaded end touching pedal arm pad).
2. Back off switch 1/4 turn, and tighten lock nuts. Clearance between threaded end of switch body and brake pedal switch contact pad should be about .012" (.30 mm). Ensure brakelights go off when pedal is released.
TESTING
POWER BRAKE BOOSTER FUNCTIONAL TEST
1. Start engine. Turn ignition off. Depress brake pedal several times. Depress pedal firmly and hold pressure for 15 seconds. If pedal sinks, master cylinder, brake line or wheel cylinder is faulty.
2. With pedal depressed, start engine. If pedal sinks slightly, vacuum unit is working properly. If pedal height does not vary, booster or check valve is faulty.
POWER BRAKE BOOSTER LEAK TEST
1. With engine running, depress brake pedal. Turn ignition off. If pedal height does not change while depressed for 30 seconds, vacuum booster is okay. If pedal rises, vacuum booster is faulty.
2. Stop engine, and depress brake pedal several times using normal pressure. Pedal height should be low when first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not vary, check power brake booster check valve.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect power brake unit vacuum hose at booster. Start engine, and allow it to idle. Ensure vacuum is available at booster end of hose. If vacuum is not available, vacuum source or check valve is faulty. Repair vacuum source or replace check valve, and retest.
REMOVAL AND INSTALLATION
FRONT DISC BRAKE PAD REMOVAL
1. Raise and support front of vehicle. Remove wheels. Remove caliper bolt and brakeline bracket bolts. Pivot caliper aside. Remove pads and pad shim. Remove pad retainers (if equipped).
2. Using a vernier caliper, measure brake friction pad thickness. Measurement does not include pad backing thickness. Minimum brake pad thickness is .06" (1.6 mm).
Replace brake pads in axle sets of 4 pads. Ensure grease, brake fluid and other contaminants do not contact lining surface. Inspect and clean rotor, and resurface it if necessary.
FRONT DISC BRAKE PAD INSTALL
1. Lubricate sliding surfaces with high temperature silicone grease. Install pad retainers. Apply Molykote M77 compound to back of pads and both sides of pad shims.
2. Install inner and outer pad shims. Install brake pads. Ensure brake pad with pad wear indicator is installed inside. Loosen bleeder screw, and slowly push piston into caliper bore.
3. Tighten bleeder screw. Ensure brake fluid does not contaminate pads. Position caliper, and install lower pin or caliper bolts. Depress brake pedal several times to seat pads. Bleed brakes as necessary. See brake bleeding procedure located on top of this page.
REAR DISC BRAKE PADS REMOVAL
Raise and support rear of vehicle. Remove wheels. Remove caliper shield (if equipped). Detach parking brake cable from caliper. Remove caliper mounting bolts. Remove caliper from bracket. Suspend caliper using wire. Remove brake pads.
To inspect rear pads use a vernier caliper, measure friction pad thickness. Service limit is .06" (1.5 mm).
REAR DISC BRAKE PADS INSTALLATION
1. Apply Molykote M77 compound to both sides of inner and outer pad shims. Install brake pads and shims. Rotate caliper piston clockwise in caliper (if necessary). Ensure cutout in piston aligns with tab on inner pad.
2. Avoid twisting piston boot. If boot is twisted, back out piston and reposition boot. Install brake caliper and parking brake cable. Install caliper shield. Tighten shield mounting bolts to specification. See bottom of page
3. Pump brake pedal several times to seat pads. Bleed brakes as necessary. See brake bleeding procedure located on top of this page.
FRONT BRAKE CALIPER REMOVAL
Front disc brake calipers are of same basic design. Only caliper-to-bracket attachments and anti-rattle springs or clips differ among models.
1. Raise and support front of vehicle. Remove wheels. Remove banjo bolt and copper washers connecting brake line to caliper. Plug hydraulic line and caliper.
2. Detach caliper guide pins or bolts, and remove caliper. DO NOT damage splash guard on upper caliper bolt side (if equipped) during removal. Remove disc pads, pad retainers, upper and lower anti-rattle springs and shim.
To install, reverse removal procedure. Install NEW copper banjo bolt washers when installing brake flexhose. Bleed brake system. See brake bleeding procedure located on top of this page.
REAR BRAKE CALIPER REMOVAL AND INSTALLATION
1. Raise and support rear of vehicle. Remove wheels. Detach caliper shield mounting bolts. Remove shield. Remove parking brake cable from caliper.
2. Remove banjo bolt and copper washers connecting brakeline to caliper. Plug hydraulic line and caliper. Detach caliper mounting bolts, and remove caliper.
To install, reverse removal procedure. Replace copper banjo bolt washers when installing brake flexhose. Bleed brake system. See brake bleeding procedure located on top of this page.
FRONT BRAKE ROTOR REMOVE AND INSTALL PROCEDURE
1. Raise and support vehicle. Remove wheels. Remove caliper assembly, and suspend it using wire. Attach dial indicator to caliper mount. Check rotor runout before
removal. See disc brake specifications on bottom of page.
2. Detach and remove two 6-mm rotor 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.
3. Clean rotor of all rust, and inspect rotor surfaces for cracks and grooves. Resurface or replace rotor as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system (if necessary). See brake bleeding procedure located on top of this page.
REAR BRAKE ROTOR REMOVAL AND INSTALLATION
1. Raise and support vehicle. Remove wheels. Remove caliper assembly. Suspend caliper using wire. Attach dial indicator to control arm assembly. Check rotor runout before removal. See specifications on bottom of page.
2. Detach and remove two 6-mm rotor 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.
3. Clean rotor of all rust, and inspect rotor surfaces for excessive wear, cracks and grooves. Resurface or replace rotor as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system (if necessary). See brake bleeding procedure located on top of this page.
To see the original article with images check it out here: Honda Civic 1992-1995 Disc and Drum Brakes: push rods, pads, calipers 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.
All models use front disc brakes. Rear brakes may be either disc type or self-adjusting drum type. Parking brake cable mechanism applies rear brakes.
BRAKE SYSTEM BLEEDING PROCEDURES
Raise and support vehicle. Fill master cylinder to maximum. Check fluid level after bleeding each wheel position. Bleed brakes in following sequence: RR, LF, LR and RF.
BRAKE PEDAL HEIGHT ADJUSTMENT
Loosen brakelight switch lock nut, and back off switch until it no longer touches brake pedal. Loosen brake pedal push rod lock nut, and screw push rod in or out until correct pedal height is obtained.
* Civic and Civic del Sol AUTOMATIC: 6.5 inches (165 mm)
* Civic and Civic del Sol MANUAL: 6.3 inches (160mm)
BRAKE WARNING LIGHT
Brake warning light indicates parking brake is engaged and/or brake fluid level is low. To adjust parking brake light operation, turn ignition on. Bend switch plate down until light comes on when parking brake lever is pulled one notch and goes out when lever is released.
MASTER CYLINDER PUSH ROD
Check and adjust master cylinder push rod-to-piston clearance before installing master cylinder.
1. Install Push Rod Adjustment Gauge (07JAG-SD40100) so gauge rod makes light contact with secondary piston of master cylinder.
Ensure gasket is in position when adjusting rod clearance.
2. Remove push rod adjustment gauge from master cylinder, and install gauge onto brake booster. See figure. Tighten mounting nuts to specification. Using engine or outside vacuum source, apply at least 10 in. Hg vacuum to brake booster. Check clearance using feeler gauge
* Civic and Civic del Sol: 0-.016" (0-.40 mm)
PARKING BRAKE
Before adjusting parking brake, loosen equalizer adjusting nut. Start engine, and depress brake pedal several times to set self-adjusting brakes before adjusting parking brake.
1. With rear brakes adjusted, raise and support rear of vehicle. Loosen equalizer nut, and pull parking brake lever up one notch. Tighten equalizer adjusting nut until rear wheels drag slightly.
2. Release parking brake lever. Rear wheels should rotate freely. Rear wheels should lock when parking brake lever is pulled up 6-10 clicks.
REAR DRUM BRAKE SHOES
Rear brake shoes will self-adjust through brake pedal action. No in-service adjustment is required.
STOPLIGHT SWITCH
1. Stoplight switch is located under dash, above brake pedal. To adjust, loosen lock nuts and turn switch until plunger is fully depressed (threaded end touching pedal arm pad).
2. Back off switch 1/4 turn, and tighten lock nuts. Clearance between threaded end of switch body and brake pedal switch contact pad should be about .012" (.30 mm). Ensure brakelights go off when pedal is released.
TESTING
POWER BRAKE BOOSTER FUNCTIONAL TEST
1. Start engine. Turn ignition off. Depress brake pedal several times. Depress pedal firmly and hold pressure for 15 seconds. If pedal sinks, master cylinder, brake line or wheel cylinder is faulty.
2. With pedal depressed, start engine. If pedal sinks slightly, vacuum unit is working properly. If pedal height does not vary, booster or check valve is faulty.
POWER BRAKE BOOSTER LEAK TEST
1. With engine running, depress brake pedal. Turn ignition off. If pedal height does not change while depressed for 30 seconds, vacuum booster is okay. If pedal rises, vacuum booster is faulty.
2. Stop engine, and depress brake pedal several times using normal pressure. Pedal height should be low when first depressed. On consecutive applications, pedal height should gradually rise. If pedal height does not vary, check power brake booster check valve.
POWER BRAKE BOOSTER CHECK VALVE TEST
Disconnect power brake unit vacuum hose at booster. Start engine, and allow it to idle. Ensure vacuum is available at booster end of hose. If vacuum is not available, vacuum source or check valve is faulty. Repair vacuum source or replace check valve, and retest.
REMOVAL AND INSTALLATION
FRONT DISC BRAKE PAD REMOVAL
1. Raise and support front of vehicle. Remove wheels. Remove caliper bolt and brakeline bracket bolts. Pivot caliper aside. Remove pads and pad shim. Remove pad retainers (if equipped).
2. Using a vernier caliper, measure brake friction pad thickness. Measurement does not include pad backing thickness. Minimum brake pad thickness is .06" (1.6 mm).
Replace brake pads in axle sets of 4 pads. Ensure grease, brake fluid and other contaminants do not contact lining surface. Inspect and clean rotor, and resurface it if necessary.
FRONT DISC BRAKE PAD INSTALL
1. Lubricate sliding surfaces with high temperature silicone grease. Install pad retainers. Apply Molykote M77 compound to back of pads and both sides of pad shims.
2. Install inner and outer pad shims. Install brake pads. Ensure brake pad with pad wear indicator is installed inside. Loosen bleeder screw, and slowly push piston into caliper bore.
3. Tighten bleeder screw. Ensure brake fluid does not contaminate pads. Position caliper, and install lower pin or caliper bolts. Depress brake pedal several times to seat pads. Bleed brakes as necessary. See brake bleeding procedure located on top of this page.
REAR DISC BRAKE PADS REMOVAL
Raise and support rear of vehicle. Remove wheels. Remove caliper shield (if equipped). Detach parking brake cable from caliper. Remove caliper mounting bolts. Remove caliper from bracket. Suspend caliper using wire. Remove brake pads.
To inspect rear pads use a vernier caliper, measure friction pad thickness. Service limit is .06" (1.5 mm).
REAR DISC BRAKE PADS INSTALLATION
1. Apply Molykote M77 compound to both sides of inner and outer pad shims. Install brake pads and shims. Rotate caliper piston clockwise in caliper (if necessary). Ensure cutout in piston aligns with tab on inner pad.
2. Avoid twisting piston boot. If boot is twisted, back out piston and reposition boot. Install brake caliper and parking brake cable. Install caliper shield. Tighten shield mounting bolts to specification. See bottom of page
3. Pump brake pedal several times to seat pads. Bleed brakes as necessary. See brake bleeding procedure located on top of this page.
FRONT BRAKE CALIPER REMOVAL
Front disc brake calipers are of same basic design. Only caliper-to-bracket attachments and anti-rattle springs or clips differ among models.
1. Raise and support front of vehicle. Remove wheels. Remove banjo bolt and copper washers connecting brake line to caliper. Plug hydraulic line and caliper.
2. Detach caliper guide pins or bolts, and remove caliper. DO NOT damage splash guard on upper caliper bolt side (if equipped) during removal. Remove disc pads, pad retainers, upper and lower anti-rattle springs and shim.
To install, reverse removal procedure. Install NEW copper banjo bolt washers when installing brake flexhose. Bleed brake system. See brake bleeding procedure located on top of this page.
REAR BRAKE CALIPER REMOVAL AND INSTALLATION
1. Raise and support rear of vehicle. Remove wheels. Detach caliper shield mounting bolts. Remove shield. Remove parking brake cable from caliper.
2. Remove banjo bolt and copper washers connecting brakeline to caliper. Plug hydraulic line and caliper. Detach caliper mounting bolts, and remove caliper.
To install, reverse removal procedure. Replace copper banjo bolt washers when installing brake flexhose. Bleed brake system. See brake bleeding procedure located on top of this page.
FRONT BRAKE ROTOR REMOVE AND INSTALL PROCEDURE
1. Raise and support vehicle. Remove wheels. Remove caliper assembly, and suspend it using wire. Attach dial indicator to caliper mount. Check rotor runout before
removal. See disc brake specifications on bottom of page.
2. Detach and remove two 6-mm rotor 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.
3. Clean rotor of all rust, and inspect rotor surfaces for cracks and grooves. Resurface or replace rotor as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system (if necessary). See brake bleeding procedure located on top of this page.
REAR BRAKE ROTOR REMOVAL AND INSTALLATION
1. Raise and support vehicle. Remove wheels. Remove caliper assembly. Suspend caliper using wire. Attach dial indicator to control arm assembly. Check rotor runout before removal. See specifications on bottom of page.
2. Detach and remove two 6-mm rotor 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.
3. Clean rotor of all rust, and inspect rotor surfaces for excessive wear, cracks and grooves. Resurface or replace rotor as necessary. To install, reverse removal procedure. Tighten retaining screws. Bleed hydraulic system (if necessary). See brake bleeding procedure located on top of this page.
To see the original article with images check it out here: Honda Civic 1992-1995 Disc and Drum Brakes: push rods, pads, calipers and more. Garage411.com
Last edited by Master23; 07-01-2009 at 06:10 PM.
Thread
Thread Starter
Forum
Replies
Last Post
Master23
Honda S2000
1
06-22-2009 12:30 PM
