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Honda Odyssey 2004. Manual - part 302

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１２

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Runout

Thickness and Parallelism

Brake Disc Runout:

Service Limit: 0.10 mm (0.004 in.)

Max. Refinish Limit: 26.0 mm (1.02 in.)

Brake Disc Thickness:

Standard: 27.9

28.1 mm (1.10

1.11 in.)

Max. Refinishing Limit: 26.0 mm (1.02 in.)

Brake Disc Parallelism:

0.015 mm (0.0006 in.) max.

19-14

Conventional Brake Components

Front Brake Disc Inspection

10 mm (0.4 in.)

108 N·m
(11.0 kgf·m, 79.6 lbf·ft)

10 mm (0.4 in.)

1. Loosen the front wheel nuts slightly. Raise the

vehicle, and support it with safety stands in the
proper locations (see page 1-15). Remove the front
wheels.

2. Remove the brake pads (see page 19-12).

3. Inspect the disc surface for damage and cracks.

Clean the brake disc thoroughly and remove all rust.

4. Use wheel nuts and suitable flat washers (A) to

hold the disc securely against the hub, then mount
a dial indicator as shown, and measure the runout
at 10 mm (0.4 in.) from the outer edge of the disc.

5. If the brake disc is beyond the service limit, refinish

the brake disc with an on-car brake lathe. The Kwik-
Lathe produced by Kwik-way Manufacturing Co.
and the ‘‘Front Brake Disc Lathe’’ offered by Snap-
on Tools Co. are approved for this operation.

NOTE:

• If the brake disc is beyond the service limit for

• A new disc should be refinished if its runout is

greater than 0.10 mm (0.004 in.).

1. Loosen the front wheel nuts slightly. Raise the

vehicle, and support it with safety stands in the
proper locations (see page 1-15). Remove the front
wheels.

2. Remove the brake pads (see page 19-12).

3. Using a micrometer, measure brake disc thickness

at eight points, approximately 45° apart and 10 mm
(0.4 in.) in from the outer edge of the brake disc.
Replace the brake disc if the smallest measurement
is less than the max. refinishing limit.

NOTE: This is the maximum allowable difference
between the thickness measurements.

4. If the brake disc is beyond the service limit for

parallelism, refinish the brake disc with an on-car
brake lathe. The Kwik-Lathe produced by Kwik-way
Manufacturing Co. and the ‘‘Front Brake Disc
Lathe’’ offered by Snap-on Tools Co. are approved
for this operation.

NOTE: If the brake disc is beyond the service limit

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refinishing, replace it (see step 7 on page 18-12).

for refinishing, replace it (see step 7 on page 18-12).

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19-15

Front Brake Caliper Overhaul

INNER PAD SHIM B

INNER PAD SHIM A

WEAR INDICATOR

OUTER PAD SHIM C

BRAKE PADS

OUTER PAD SHIM D

’99 Model:

’00-02 Models:
’02-04 Models have
one pair of the
pad shim.

PISTON

PISTON BOOT

PISTON SEAL

BRAKE HOSE

8 x 1.0 mm
26 N·m
(2.7 kgf·m,
20 lbf·ft)

BANJO BOLT
34 N·m
(3.5 kgf·m,
25 lbf·ft)

SEALING WASHERS

BLEED SCREW
9.8 N·m (1.0 kgf·m,
7.2 lbf·ft)

CALIPER BODY

FLANGE BOLTS
12 x 1.25 mm
108 N·m
(11.0 kgf·m,
79.6 lbf·ft)

PIN BOOT

CALIPER
BRACKET

PAD RETAINERS

CALIPER
BRACKET

BUSHING

PIN

SUB PIN

MAIN PIN

: Honda caliper grease (P/N 08C30-B0234M)

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Remove, disassemble, inspect, reassemble, and install the caliper, and note these items:

• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off

immediately with water.

• To prevent dripping brake fluid, cover disconnected hose joints with rags or shop towels.
• Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
• Before reassembling, check that all parts are free of dust and other foreign particles.
• Replace parts with new ones as specified in the illustration.
• Make sure no dirt or other foreign matter gets in the brake fluid.
• Make sure no grease or oil gets on the brake discs or pads.
• When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
• Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid. Non-Honda brake fluid can cause

corrosion and shorten the life of the system.

• Do not mix different brands of brake fluid as they may not be compatible.
• Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
• Replace all rubber parts with new ones whenever disassembled.
• After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

Install inner pad with
its wear indicator upward.

Replace.

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０１

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19-16

Conventional Brake Components

Master Cylinder Replacement

Master Cylinder Inspection

E
25 N·m (2.5 kgf·m, 18 lbf·ft)

D
ABS:
10 x 1.0 mm
15 N·m
(1.5 kgf·m,
11 lbf·ft)

ABS/TCS:
12 x 1.0 mm
19 N·m
(1.9 kgf·m,
14 lbf·ft)

RESERVOIR

RESERVOIR CAP

RESERVOIR SEAL

STRAINER

MASTER CYLINDER

SCREW

SEAL

GROMMETS

Do not spill brake fluid on the vehicle; it may
damage the paint; if brake fluid does contact the
paint, wash it off immediately with water.

1. Disconnect the brake fluid level switch connectors

(A), and remove the reservoir cap (B).

2. Remove the brake fluid from the master cylinder

reservoir (C) with a syringe.

3. Disconnect the brake lines (D) from the master

cylinder. To prevent spills, cover the hose joints
with rags or shop towels.

4. Remove the master cylinder mounting nuts (E).

5. Remove the master cylinder (F) from the brake

booster (G). Be careful not to bend or damage the
brake lines when removing the master cylinder.

6. Install the master cylinder in the reverse order of

removal.

NOTE:

• Before reassembling, check that all parts are free of

dust and other foreign particles.

• Do not try to disassemble the master cylinder

assembly. Replace the master cylinder assembly with
a new part if necessary.

• Do not allow dirt or foreign matter to contaminate the

brake fluid.

Check for damage.

Check for blockage
of vent holes.

Check for damage and
deterioration.

Remove accumulated
sediment.

Check for leaks, rust, and
damage.

Check for damage and
deterioration.

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Functional Test

Leak Test

19-17

Brake Booster Test

1. With the engine stopped, press the brake pedal

several times to deplete the vacuum reservoir, then
press the brake pedal hard and hold it for
15 seconds. If the brake pedal sinks, either the
master cylinder is bypassing internally, or the
brake system (master cylinder, lines, modulator, or
caliper) is leaking.

2. Start the engine with the brake pedal pressed. If the

pedal sinks slightly, the vacuum booster is
operating normally. If the pedal height does not
vary, the booster or check valve is faulty.

3. With the engine running, press the brake pedal

lightly, and shift the transmission to the D position.
Apply just enough pressure to hold back automatic
transmission creep. If the brake pedal sinks more
than 10 mm (3/8 in.) in 3 minutes, 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 the booster.)

1. Press the brake pedal with the engine running, then

stop the engine. If the pedal height does not vary
while pressed for 30 seconds, the vacuum booster
is OK. If the pedal rises, the booster is faulty.

2. Turn the engine off, and wait 30 seconds. Press the

brake pedal several times using normal pressure.
When the pedal is first pressed, it should be low.
On consecutive applications, the pedal height
should gradually rise. If the pedal position does not
vary, check the booster check valve.

3. Disconnect the brake booster vacuum hose at the

booster (A). The check valve (B) is built into the
hose.

4. Start the engine, and let it idle. There should be

vacuum available. If no vacuum is available, the
check valve is not working properly. Replace the
brake booster vacuum hose and check valve and
retest.

5. Start the engine, and then pinch the brake booster

vacuum hose between the check valve, and the
booster.

6. Turn the engine off, and wait 30 seconds. Press the

brake pedal several times using normal pressure.
When the brake pedal is first pressed, it should be
low. On consecutive applications, the brake pedal
height should gradually rise.

• If the pedal position does not vary, replace the

brake booster.

• If the pedal position varies, replace the brake

booster vacuum hose/check valve assembly.

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