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Honda S2000 Brake System

Honda S2000

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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). See figure.
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). See figure. 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). See figure.

When brake pedal is released, the brake pedal position switch is normally open and the idle stop switch is normally closed.

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.


PARKING BRAKE SWITCH
Brake warning light indicates parking brake is engaged and/or brake fluid level is low. To adjust parking brake light switch, 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 pushrod-to-piston clearance before installing master cylinder.

1. Install and adjust pushrod Adjustment Gauge (07JAG-SD40100) on master cylinder body. Push in center shaft until top of it contacts end of secondary piston by turning adjusting nut. See figure. Ensure gasket is in position when adjusting rod clearance.
2. Without disturbing center shaft's position, install the pushrod adjustment gauge backwards on booster. Install master cylinder nuts, and tighten to specifications. Connect booster in-line with a 0-30 in. Hg vacuum gauge to booster's engine vacuum supply, and maintain an engine speed that will deliver 20 in. Hg of vacuum.
3. With a feeler gauge, measure clearance between gauge body and adjusting nut. See figure. If clearance between gauge body and adjusting nut is .02" (.44 mm) the pushrod-to-piston clearance is 0 mm. However, if the clearance between gauge body and adjusting nut is 0 mm, the pushrod-to-piston clearance is .02" (.4 mm) or more. Therefore it must be adjusted and rechecked.
4. If clearance is incorrect, loosen star lock nut and turn adjuster in or out to adjust. Adjust clearance while the specified vacuum is applied to booster. Hold clevis while adjusting. See figure. Tighten star lock nut securely. Remove pushrod adjustment gauge. Check brake pedal pushrod length. Brake pedal pushrod length should be 4.6" (116 mm). If length is incorrect, loosen pushrod lock nut, and turn clevis in or out to adjust. See figure.

PARKING BRAKE CHECK
Pull parking brake lever with 44 lbs. (196 N) of force to fully apply parking brake. Parking brake lever should
be locked with the specified number of clicks.

PARKING BRAKE ADJUSTMENT
After rear brake servicing, loosen parking brake adjusting nut, start engine, and press brake pedal several times to set self-adjusting brake before adjusting parking brake. See figure.

1. Adjust parking brake if lever clicks are out of specification. Block front wheels, then raise rear of vehicle, and make sure its securely supported. On vehicles with rear disc brakes, make sure parking brake arm on rear brake caliper contacts brake caliper pin. See figure. Pull parking brake lever up one click. Remove center console or rear console lid for access to adjuster nut. Tighten adjusting nut until parking brakes drag slightly when rear wheels are turned. See figure.
2. Release brake lever fully and check that parking brakes do not drag when rear wheels are turned. Repeat if necessary. Make sure parking brakes are fully applied when parking brake lever is pulled up fully. Reinstall console.


HONDA S2000 BRAKE SYSTEM TROUBLE SHOOTING


BRAKE SYSTEM OPERATION
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RAPID BRAKE PAD WEAR, VEHICLE VIBRATION (AFTER A LONG DRIVE), OR HARD BRAKE PEDAL
1. Drive the vehicle until the brakes drag or until the pedal is high and hard. This can take 20 or more brake pedal applications during an extended test drive.
2. With the engine running, raise the vehicle on a lift, and spin all four wheels by hand. Is there brake drag at any of the wheels? If yes, go to next step. If no, look for other causes of the pad wear, high pedal, or vehicle vibration.
3. Turn the engine off, pump the brake pedal to deplete the vacuum in the brake booster, and then spin the wheels again to check for brake drag. Is there brake drag at any of the wheels? If yes, go to next step. If no, replace the brake booster.
4. Without removing the brake lines, unbolt and separate the master cylinder from the booster, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? If yes, go to next step. If no, check the brake pedal position switch adjustment and pedal free play.
5. Loosen the hydraulic lines at the master cylinder, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? If yes, go to next step. If no, replace the master cylinder.
6. Loosen the bleed screws at each caliper and wheel cylinder, then spin the wheels to check for brake drag. Is there brake drag at any of the wheels? If yes, disassemble and repair the caliper or wheel cylinder on the wheel(s) with brake drag. If no, look for and replace any damaged brake lines. If all brake lines are OK, replace the ABS modulator unit (if equipped) or proportioning control valve.


TESTING AND INSPECTION




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 more than .4" (10 mm) in 3 minutes, the master cylinder is faulty. A slight change in pedal height is normal. (The AC compressor load changes the vacuum available to booster.) Leak Test

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. Booster Check Valve Test

Booster Check Valve Test
Disconnect brake booster vacuum hose at booster. Check valve is built into hose. See figure. Start engine, and let it idle. There should be vacuum available. If no vacuum is available, check if valve is not working properly. Replace brake booster vacuum hose and check valve, and retest.


BRAKE FLUID LEVEL SWITCH
Remove reservoir cap. Check that float moves up and down freely; if it doesn't, replace reservoir cap assembly. Check for continuity between terminals with float in down position and up position. With the float up, there should be no continuity. With float down, there should be continuity.

BRAKE HOSE AND LINE
Replace the brake hose clip whenever the brake hose is serviced. Always use NEW sealing washers on banjo bolts.

Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. Check for leaks at hose and line joints or connections, and retighten if necessary. Check the master cylinder and ABS modulator unit (if equipped), for damage and leakage.

FRONT BRAKE DISC
Runout
Raise and support vehicle. Remove front wheels. Remove brake pads. Inspect disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Use wheel nuts and suitable flat washers to hold disc securely against hub, then mount a dial indicator to brake and measure runout at .4" (10 mm) from outer edge of disc.

If disc is beyond service limit, refinish brake disc with an on-car brake lathe.

FYI: A new disc should be refinished if its runout is greater than service limit.

Thickness and Parallelism
Raise and support vehicle. Remove wheels. Remove brake pads. Using a micrometer, measure disc thickness at 8 points approximately 45 degrees apart and .4" (10 mm) in from outer edge of disc. Replace brake disc if smallest measurement is less than the MAX. refinishing limit.

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

If the disc is beyond the service limit for parallelism, refinish brake disc with an on-car brake lathe. If it is beyond service limit for refinishing, replace the brake disc.

PARKING BRAKE SWITCH
Remove console, and disconnect connector from switch. See figure. Check for continuity between positive terminal and body ground. With brake lever up, there should be continuity. With brake lever down, there should be no continuity. If vehicle is equipped with ABS and both ABS indictor and brake system indicator come on at the same time, diagnose anti-lock brake system.

REAR BRAKE DISC

Runout
Raise and support vehicle. Remove wheels. Remove brake pads. Inspect disc surface for damage and cracks. Clean disc thoroughly, and remove all rust. Use wheel nuts and suitable flat washers to hold disc securely against hub, then mount a dial indicator to brake and measure runout at .4" (10 mm) from outer edge of disc.
If disc is beyond service limit, refinish brake disc. A new disc should be refinished if its runout is greater than .004" (.10 mm)

Thickness and Parallelism
Raise, support, and remove wheels. Remove brake pads. Using a micrometer, measure disc thickness at 8 points approximately 45° apart and .4" (10 mm) in from outer edge of disc. Replace brake disc if smallest measurement is less than the MAX. Refinishing limit. If the disc is beyond the service limit for parallelism, refinish brake disc.

If it is beyond service limit for refinishing, replace.


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. See figure. 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.

FRONT AND REAR BRAKE DISC REMOVAL AND INSTALLATION
1. 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.
2. 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.
3. 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.

OVERHAUL


DISC BRAKE CALIPER OVERHAUL
For exploded views of front and rear disc brake calipers, See figure 1. and See figure 2.


SPECIAL TOOLS
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TORQUE SPECIFICATIONS Ft. Lbs. (N.m)



TORQUE SPECIFICATIONS INCH Lbs. (N.m)






Honda S2000 AP1

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