Brake Caliper Overhaul

DISASSEMBLY PROCEDURE

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) can fly out with force and could result in serious bodily injury.

NOTICE:
- 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.
- Use clean cloths 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.

1. Remove the caliper.





2. Remove the piston. Blow compressed air into the caliper inlet hole (2). The piston will come out through the piston boot.
3. Inspect the piston for the following conditions:
- Scoring
- Nicks
- Corrosion
- Worn or damaged chrome plating
Replace the piston if any of the above conditions are found.





4. Remove the caliper boot (2). Do not scratch the housing bore.





5. Remove the piston seal (4) from the groove in the caliper bore. Use a small wooden or plastic tool.
6. Inspect the caliper bore and the seal grooves for the following conditions:
- Scoring
- Nicks
- Corrosion
- Wear
7. Use a crocus cloth in order to polish out light corrosion.
8. Replace the caliper housing (3) if corrosion in and around the seal groove cannot be cleaned with a crocus cloth.
9. Inspect the bolt boots (2) for the following conditions:
- Cuts
- Tears
- Deterioration





10. Replace any damaged boots.





11. Inspect the caliper bolts (3) for corrosion or damage. Replace any corroded bolts. Do not attempt to polish away corrosion.
12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper (1) if the seal groove is damaged.
13. Remove the bleeder valve cap and the bleeder valve (4) from the caliper housing.
14. Clean all the parts in clean, denatured alcohol.
15. Dry all the parts with filtered, non-lubricated compressed air.
16. Blow out all the passages in the caliper housing and the bleeder valve. Use filtered, non-lubricated compressed air.

ASSEMBLY PROCEDURE

- Tools Required
- J 36349 Front Dust Boot Seal Installer

NOTICE: Refer to Fastener Notice in Service Precautions.





1. Install the bleeder valve (2) into the caliper housing.
- Tighten the bleeder valve to 13 Nm (115 inch lbs).
2. Install the bleeder valve cap (1) onto the bleeder valve.
3. Install a new lubricated piston seal (4) into the caliper bore grooves. Ensure that the piston seal is not twisted.





4. Install the lubricated boot (1) onto the piston (2).
5. Lubricate the piston OD with clean brake fluid.
6. Install the piston and the boot into the bore of the caliper. Push the piston to the bottom of the bore.





7. Seat the caliper boot in the caliper housing (1) counterbore using the J 36349.
8. Install the caliper.