Removal and Installation

Fig. 4 Removing Caliper Piston Inner Seal:

DISASSEMBLY

1. Follow steps 1 through 5, refer to Brakes and Traction Control/Brakes/Brake Pads/Service and Repair.
2. Disconnect brake hose from caliper, and cap open line to prevent dirt from entering system. Discard brake hose copper washers.
3. Clean caliper exterior with suitable brake cleaning solvent.
4. Drain caliper, then place on clean work surface.
5. Using screwdriver, loosen metal lip of caliper piston dust seal.
6. Place a block of wood between caliper and caliper piston, then using compressed air, gently apply air pressure into caliper fluid inlet hole to ease piston out of bore. Do not place fingers in front of piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury.
7. Using a feeler gauge or other suitable tool, remove piston inner seal.

INSPECTION

1. Inspect caliper bore for scoring or corrosion. Light corrosion and scoring can be removed with brake hone, using brake fluid for lubricant. Do not attempt to clean caliper bore with any other abrasives.
2. Clean caliper with suitable brake cleaning solvent, then dry with compressed air.
3. Inspect caliper hardware for corrosion and replace as necessary.
4. Inspect caliper piston for corrosion, scoring or wear, replacing as necessary. Light corrosion on piston may be cleaned with mineral spirits. Never sand or apply abrasive cleaners to piston.

ASSEMBLY

1. Lubricate piston bore and new inner seal with brake fluid, then work seal into caliper bore groove by hand.
2. Lubricate piston with brake fluid, then slide metal portion of new dust seal over open end of piston and pull rearward until seal inner lip seats in piston groove, then push outer portion of seal forward until it is flush with end of piston.
3. Insert piston and seal assembly into bore. Do not unseat inner seal. With a slight rocking motion, bottom piston into bore.
4. Center seal lip into counterbore on caliper, then seat seal into caliper housing using tool No. Fre. KM.02 and adapter No. Fre. ML.02 or equivalents.

INSTALLATION

1. Position caliper over brake pads and onto caliper mounting bracket.
2. Lubricate mounting pins with suitable grease, and install through caliper sleeves and bushings. Thread pins into mounting bracket and torque to 18 1/2 lb-ft.
3. Using a new copper washer, install brake hose in caliper and torque to 13 lb-ft, Ensure hose is not twisted.
4. Fill master cylinder with clean brake fluid and bleed brakes.
5. Install wheel and tire assembly, then lower vehicle.