Brake Caliper

BRAKE CALIPER

REMOVAL
REAR





1. Install prop rod on the brake pedal to keep pressure on the brake system.
2. Raise and support vehicle.
3. Remove the wheel and tire assembly
4. Remove the brake hose banjo bolt (3) if replacing caliper.
5. Remove the caliper mounting slide pin bolts (2).
6. Remove the caliper from vehicle.

DISASSEMBLY





1. Remove brake shoes from caliper.
2. Drain brake fluid out of caliper.
3. Take a piece of wood and pad it with one-inch thickness of shop towels (1). Place this piece in the outboard shoe side of the caliper in front of the piston. This will cushion and protect caliper piston during removal.





4. Remove caliper piston (2) with short bursts of low pressure compressed air. Direct air through fluid inlet port and ease piston out of bore.

CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out.

WARNING: Never attempt to catch the piston as it leaves the bore. This may result in personal injury.





5. Remove caliper piston dust boot with suitable pry tool (1).





6. Remove caliper piston seal with wood or plastic tool (1). Do not use metal tools as they will scratch piston bore.





7. Remove caliper mounting bolt bushings (1) and boots (2).

CLEANING
Clean the caliper components with clean brake fluid or brake clean only Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.

CAUTION: Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal.

INSPECTION
The piston is made from a phenolic resin (plastic material) and should be smooth and clean.
The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing.

CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.





The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch).

ASSEMBLY

CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.





1. Lubricate caliper piston bore, new piston seal and piston with clean brake fluid.
2. Lubricate caliper bushings and interior of bushing boots with silicone grease.
3. Install bushing boots (2) in caliper, then insert bushing into boot and push bushing (1) into place.





4. Install new piston seal into seal groove (1) with finger.





5. Install new dust boot on caliper piston and seat boot in piston groove (1).





6. Press piston (1) into caliper bore by hand, use a turn and push motion to work piston into seal.
7. Press caliper piston to bottom of bore.





8. Seat dust boot (3) in caliper with Installer Tool C-4842 (2) and Tool Handle C-4171 (1).
9. Replace caliper bleed screw if removed.

INSTALLATION





1. Install the brake pads if removed.
2. Lubricate anti-rattle clips (2) for the disc brake pads.





3. Install caliper to the caliper adapter.
4. Coat the caliper mounting slide pin bolts (1) with silicone grease. Then install and tighten the bolts to 15 Nm (11 ft. lbs.).
5. Install the brake hose banjo bolt if removed.

CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt.

6. Install the brake hose to the caliper with new seal washers and tighten fitting bolt to 31 Nm (23 ft. lbs.).
7. Remove the prop rod from the vehicle.
8. Bleed the base brake system.
9. Install the wheel and tire assemblies.
10. Remove the supports and lower the vehicle.
11. Verify a firm pedal before moving the vehicle.