Disassembly and Assembly

Disassembly and Assembly of Brake Caliper Assembly

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NOTE: Do not remove torque member, brake pads, shims, shim covers and pad retainers, when disassembling or assembling cylinder body.

DISASSEMBLY





1. Remove caliper assembly from vehicle.
2. Remove sliding pin bolts from cylinder body, and remove pads, shims, shim cover and pad retainers from torque member.

CAUTION: When removing pad retainer from torque member, lift the pad retainer in the direction shown by arrow (shown in the figure) so as not to deform it.





3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.

CAUTION: Do not get fingers caught in the pistons.





5. Using a flat-bladed screwdriver, remove piston seals from cylinder body.

CAUTION: Be careful not to damage the inner wall of cylinder.

INSPECTION AFTER DISASSEMBLY
Cylinder Body

CAUTION: Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

^ Check the inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cylinder body.
^ Minor flaws caused by corrosion or a foreign material can be removed by polishing a surface of the inner wall with a fine sandpaper. Replace cylinder body, if a malfunction is detected.

Torque Member
Check for wear, cracks, and damage. If a malfunction is detected, replace applicable part.

Piston

CAUTION: The piston sliding surface is plated. Do not polish with sandpaper.

Check piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.

Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins and sliding pin boots for wear, damage, and cracks. If a malfunction is detected, replace applicable part.

ASSEMBLY

CAUTION: When assembling, use only rubber lubricant specified below.





1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body.

CAUTION: Do not reuse piston seal.





2. Apply rubber grease to piston boots. Cover the piston end with piston boot, and install cylinder-side lip on piston boot properly into groove on cylinder body.

CAUTION: Do not reuse piston boot.





3. Apply brake fluid to piston, and press piston into cylinder body by hand to assemble piston-side lip on piston boot properly into a groove on piston.

CAUTION: Press piston evenly and change pressing point to prevent inner wall of cylinder from being rubbed.

4. Install sliding pins and sliding pin boots to the torque member.





5. Install the torque member to the steering knuckle and tighten the mounting bolts to the specified torque. Refer to BR-25, "Components".

CAUTION: Before installing torque member to vehicle, wipe off oil and grease on the washer seats on steering knuckle and the mounting surface of the torque member.

6. Install pad retainers to torque member.
7. Press in piston until pads can be installed, and then install cylinder body to torque member.
8. Install cylinder body, and tighten sliding pin bolt to the specified torque. Refer to BR-25, "Components".
9. Position a projection of brake hose metal fitting by aligning with protrusions on cylinder body and tighten union bolt to specified torque.

CAUTION:
^ Assemble brake hose securely to cylinder body.
^ Do not reuse copper washer for union bolts.

10. After installing caliper assembly, refill with new brake fluid and bleed air.