Repair

Front Brake Caliper Components:

DISASSEMBLE
1. Remove caliper from vehicle. Refer to Front Brake Caliper Replacement.
2. Caliper bolt bushings (3).
a. Inspect Caliper bolt bushings (3) for nicks or cuts. Replace if damaged.
b. Inspect Mounting bores for corrosion. If mounting bores show signs of corrosion, remove corrosion using a 1-inch wheel cylinder honing brush. Clean mounting bores with clean denatured alcohol.

CAUTION: Do not place fingers in front of the caliper piston(s) In an attempt to catch or protect it when applying compressed air. The piston(s) may come out with force resulting in serious injury.

NOTE: Use clean clothes to pad interior of caliper housing during piston removal. Use just enough air to ease the piston out of the bore. If the piston is blown out, even with the padding provided, it may be damaged.

Removing Front Brake Caliper Piston:

3. Caliper piston (9) from caliper housing (12). Apply compressed air to housing inlet hole. Piston (9) for scoring, nicks, corrosion, and worn or damaged chrome plating. Replace piston if any of above are found.

Removing Front Brake Caliper Piston Boot:

4. Caliper piston boot (8) from caliper housing (12).

NOTE: Do not use a metal tool to remove the piston seal from the caliper housing bore. Using a metal tool may damage the caliper bore or seal groove.

5. Piston seal (10) from caliper housing (12). Inspect Caliper bore and seal groove for scoring, nicks, corrosion, and wear. Use crocus cloth to polish out light corrosion. Replace caliper housing (12) if corrosion in and around seal groove will not clean up with crocus cloth.
6. Brake bleeder screw cover (20) and caliper bleeder valve (11) from caliper housing (12).

ASSEMBLE

NOTE: Clean All parts in clean denatured alcohol. Dry with unlubricated compressed air. Blow out all passages in caliper housing (12) and bleeder valve (11).

1. Lubricate all rubber parts with clean brake fluid.
2. Caliper bleeder valve (11) into caliper housing (12). Tighten Caliper bleeder valve (11) to 13 Nm (115 inch lbs.).
3. Replace bleeder screw cover (20).
4. Piston seal (100) into bore groove of caliper housing (12). Make sure piston seal (10) is not twisted.

Installing Front Brake Caliper Piston Boot:

5. Caliper piston boot (8) onto caliper piston (9).
6. Piston (9) with assembled boot (8) into bore of housing (12). Push piston (9) to bottom of housing bore.

Seating Front Brake Caliper Piston Boot:

7. Seat boot (8) into counterbore of caliper housing (12) using J 26267.
8. Caliper bolt bushings (3). Lubricate beveled end of bushings (3) with silicone grease. Pinch bushings (3) and install beveled end first. Push bushings (3) through housing mounting bore.
9. Install caliper. Refer to Front Brake Caliper Replacement.