Brake Caliper Overhaul

REMOVAL PROCEDURE
1. Remove the caliper.
2. Drain all the brake fluid from the caliper.





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.

Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding.

3. Pad the interior of the caliper with clean shop towels.
4. Remove the piston from the caliper bore.





5. Remove the boot from the caliper bore. Do not scratch the housing bore.





6. Remove the piston seal from the caliper bore. Do not use a metal tool.





7. Remove the bleeder valve from the caliper body.
8. Clean the bleeder valve, the caliper bore, the caliper passages and the piston with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air.
9. Inspect the piston and the caliper for the following conditions:
^ Scoring on the piston surface or in the caliper bore
^ Corrosion on the piston
^ Chrome plating damage on the piston
^ Corrosion in the caliper bore

Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed.

^ Pitting in the caliper bore
10. Replace the piston or the caliper if you found any of the above conditions.

INSTALLATION PROCEDURE

^ Tools Required
- J 26267 Piston Seal Installer





1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid.





2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove.





3. Install the boot on the piston.





4. Install the piston in the caliper bore.





5. Install the boot into the caliper housing bore using the J 26267.

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.





6. Install the bleeder valve in the caliper body.
^ Tighten the bleeder valve to 13 Nm (115 inch lbs.).