Disassembly and Assembly

NOTE: Tool reference # J-33028, dust boot installer, required.

DISASSEMBLY

CAUTION: Disassemble and overhaul the brake calipers only in a clean work area.

1. Clean the outside of the caliper with brake cleaning solvent.

Padding Piston:

2. Drain the fluid from the caliper and pad the caliper piston (1) with clean shop cloths (2).
3. Apply compressed air at the fluid inlet port (3) and slowly pressurize the caliper to ease the piston out of the bore.
4. Use a screwdriver to remove the dust boot (4). Discard the boot.

CAUTION: Do not scratch the caliper piston bore during overhaul.

Caliper Components:

5. Remove the piston seal (1) with a suitable tool made of wood or plastic. Discard the seal.
6. Remove the bleeder screw (2).
7. Remove the inner and outer bushings (3) from the caliper mounting ears and discard
8. Clean all the components with brake cleaning fluid and compressed air.
9. Replace the mounting pins (4) if they are corroded or have damaged threads.
10. Replace the caliper piston (6) if it is damaged or corroded.
11. Replace the caliper if the piston bore is damaged or corroded.

ASSEMBLY
1. Lubricate the piston bore and replacement piston seal (1) with brake
fluid.



2. Install a replacement dust boot (7) on the piston. Slide the metal retainer part (8) of the boot (7) over the open end of the piston (6) and pull the boot rearward until the boot lip seats in the piston groove (9).



3. Push the metal retainer part (8) of the boot forward until the retainer is flush with the rim at the open end of the piston. Snap the seal fold (10) into place.
4. Install the piston into the caliper bore. Do not unseat the piston seal.
5. Install the seal in the bore groove by hand. Lubricate the piston (6) with brake fluid.

Installing Dust Seal:

6. Press the piston to the bottom of the caliper bore, Seat the metal retainer part of the dust boot in the counterbore at the upper end of the bore with tool J-33028.
7. Install the bleeder screw and replacement inner and outer bushings in the caliper mounting ears.
8. Install the caliper.