Remove/Install

REMOVAL

1. Remove the nuts and bolts securing the tie-plate to the rear suspension unit and remove the tie-plate.





2. Ensure that the Handbrake lever is in the fully OFF position. Lift the carpet adjacent to the hand brake lever mounting for access to the cable adjusting nuts (1).
3. Slacken the cable lock\adjusting nuts.





4. Release the springs (1) from the Handbrake caliper arms. Move the right-hand arm (when viewed from the rear of the car), to the centre line of the car, allowing the end of the inner (operating) cable (2) to be detached from the operating arm.
5. Slide the rubber cover from the outer cable (3) and release the outer cable from the other hand brake operating arm. Position the hand brake cable clear of the caliper.
6. Push back the locktabs (4), securing the Handbrake caliper mounting bolts.
7. Remove the two mounting bolts, tab washer and retraction plate.
8. Slide the hand brake caliper around the brake disc, and withdraw through the gap exposed by the removal of the tie-plate.





9. Remove the brake pad securing clips (1), retaining pins (2) and brake pads (3) from the caliper.

10. Loosen the caliper feed pipe union at the three way connector and disconnect the feed pipe from the caliper. Plug the ports to prevent the loss of fluid and ingress of dirt.
11. Break the locking wire and remove the caliper mounting bolts.
12. Slide the caliper around the brake disc and withdraw through the gap exposed by the removal of the tie-plate.

INSTALLATION

1. If the caliper is being replaced, transfer the bridge pipe to the new caliper.
2. Place the caliper in the mount position. Locate and loosely install the upper caliper securing bolt. Position the caliper and install the lower caliper bolt. Tighten the bolts to 68 to 81 Nm (50.3 to 59.9 ft lb).





3. Lock wire the caliper bolt heads. Pick up the Handbrake caliper and holding the lever/carrier in one hand, de-adjust (unwind) the remaining carrier, until the distance between pad faces is approximately 19 mm (3/4 in).
4. Place the Handbrake caliper in the mounting position. Install the retractor plate and a new tab washer, fit and tighten the securing bolts to20 to 25 Nm (14.8 to 18.5 ft lb). Lock over the tabs.
5. Install and tighten the brake feed pipe to 10 to 12 Nm (7.4 to 8.8 ft lb) ensuring that the T piece union is tight.





6. Refit the brake pads (3), retaining pins (2) and securing clips (1).
7. Install the Handbrake cable into the levers and refit the return spring. Refit the rubber boot over the cable. Operate the Handbrake actuating lever until the adjuster ratchet ceases to click. The pads are now adjusted to the correct clearance.
8. Install the suspension tie plate.
9. Adjust the Handbrake cable in the car so that with the hand brake fully OFF, there is a small amount of slack in the cable.





10. Tighten the cable adjuster/locknut (1) 19 to 24 Nm (14 to 17.7 ft lb) and refit the sill carpet.
11. Top up the brake fluid reservoir (to the base of the filler neck) with NEW brake fluid from a sealed container.
12. Bleed the Brakes. Brake Bleeding