Brake Caliper Overhaul

REMOVAL PROCEDURE





1. Remove the caliper from the vehicle.
2. Remove the caliper set ring (3) and the piston boot (2).

Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.





3. Insert a block of hard wood or a shop cloth (2) into the caliper interior. This will catch the piston as the piston is forced out of the bore with compressed air.
4. Remove the piston from the caliper (1) by applying compressed air to the caliper brake hose connector hole.





5. Remove the piston seal from the caliper housing by using a screwdriver.





6. Remove the sliding pins from the caliper carrier (1).
7. Remove the dust boots (2) from the caliper carrier using a dull chisel and a hammer.
8. Remove the bleeder valve from the caliper.
9. Clean the following components in denatured alcohol:
^ The caliper slide bushings
^ The caliper set ring
^ The piston
^ The caliper carrier
^ The caliper housing
10. Dry the components using unlubricated, compressed air.
11. Blow out all passages in the caliper housing and bleeder valve.
12. Inspect the following components for damage, wear or corrosion:
^ The caliper housing
^ The caliper carrier
^ The piston
^ The piston seal
^ The piston boot
^ The caliper slide bushing
^ The caliper set ring
13. Replace the components if damage, wear or corrosion is evident.

INSTALLATION PROCEDURE





1. Lubricate all rubber parts with clean brake fluid.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the bleeder valve to the caliper.
^ Tighten the bleeder valve to 8.3 Nm (74 lb in).
3. Lubricate the two new dust boots (2) with Lithium soap base glycol grease.
4. Install the two new dust boots (2) onto the caliper carrier (1). Use a wrench and a hammer in order to tap the dust boots onto the caliper carrier. Ensure that the metal plate portion of the dust boot fits snugly in the torque plate.
5. Lubricate the two sliding pins with Lithium base glycol grease.
6. Insert the sliding pin with the sliding bushing into the lower portion of the torque plate.
7. Insert the sliding pin without the sliding bushing into the upper portion of the torque plate.
8. Lubricate the following components with Lithium soap base glycol grease:
^ The piston
^ The seal
^ The cylinder boot
9. Install the piston seal and piston into the caliper housing.
10. Install the piston boot and caliper set ring into the caliper housing.

Important: Ensure that the dust boots are secured firmly into each caliper groove.

11. Install the caliper to the vehicle.