Disassembly and Assembly

Disassembly and Assembly of Caliper Assembly

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

DISASSEMBLY
1. Remove the slide pin bolt, and then remove cylinder body from torque member.

CAUTION: Do not drop pads, shims, shim cover and pad retainer from torque member.

2. Remove sliding pin boot from torque member.





3. As shown in the figure, using a flat-bladed screwdriver, remove the retaining ring from the cylinder body.





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 piston.





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

CAUTION: Be careful not to damage cylinder inner wall.

CALIPER INSPECTION
Cylinder Body

CAUTION:
^ Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
^ Check inner wall of cylinder for corrosion, wear, and damage. If any non-standard condition is detected, replace cylinder body.
^ Minor flaws caused by corrosion or a foreign material can be removed by polishing the surface with a fine sandpaper. Replace the cylinder body, if necessary.

Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.

Piston

CAUTION: Since the piston surface is plated, do not repair using sandpaper.

Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected, replace applicable part.

Sliding Pin Bolts and Sliding Pin Boots
Check that there is no wear, damage, or cracks in the sliding pin bolts and sliding pin boots, and if there are, replace them.

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 boot. Cover the piston end with the piston boot, and then install cylinder slide lip on the piston boot securely into the groove on cylinder body.

CAUTION: Do not reuse the piston boot.





3. Apply a brake fluid to the piston, insert into the cylinder body by hand and firmly attach the piston boot piston-side lip into the piston groove.

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





4. Fix piston boot with retaining ring.

CAUTION:
^ Make sure the boot is firmly in the cylinder body groove.
^ Do not reuse the retaining ring.

5. Install the sliding pin bolt and sliding pin boot to the torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the rear of the pad and to both sides of the shim, and attach the inner shim and shim cover to the inner pad, and the outer shim to the outer pad.





7. Install the pad retainer and pad to the torque member.

CAUTION: When attaching the pad retainer, attach it firmly so that it does not float up higher than the torque member, as shown in the figure.

8. After assembling shims and shim covers to pad, install it to the torque member.
9. Install cylinder body. Tighten sliding pin bolts to the specified torque.