Rear

Fig. 4 Exploded view of rear caliper piston:

DISASSEMBLY

1. Remove caliper assembly and brake pads as previously described.
2. Remove slide pin bolts and the slide pins from anchor bracket.
3. Secure caliper assembly in a suitable vise.
4. Turn caliper piston counterclockwise using piston adjuster tool No. T87P-2588-A or equivalent, until it protrudes approximately .8 inch.
5. Disengage piston boot cover from piston groove, then turn piston fully out of housing using adjuster tool.
6. Remove piston boot, then the piston body snap ring, Fig. 4.
7. Remove adjuster nut with thrust washers, wave washers and thrust bearing.
8. Remove and discard adjuster nut seal. Note direction of seal lip for installation reference.
9. Clean adjuster nut clutch surface and ensure piston breather port in piston groove is not restricted.
10. Remove piston seal from caliper body.
11. Remove circlip, then the washer, spring and spring cover housing from caliper.
12. Remove fast thread adjuster and snap ring retaining key plate from caliper. Remove and discard O-ring from adjuster.
13. Remove parking brake strut from bore.

Fig. 21 Parking Brake Lever Return Spring:

14. Remove parking brake lever return spring from lever, then remove stop bolt, Fig. 5.
15. Remove parking brake lever return spring from caliper bore. Remove and discard shaft seal.
16. Clean and inspect all caliper components, replacing as necessary.

Fig. 22 Rear Caliper Lever Shaft Bushing Installation:

ASSEMBLY

1. Install new lever shaft bushing, if previously removed, to a depth of .29 inch from lower seal lip, Fig. 6. Ensure cutout in bushing is properly aligned with pushrod bore.
2. Apply suitable grease to lever shaft and bushing.
3. Press shaft seal into housing until it is fully seated on shoulder.
4. Slide lever into housing through seal, using care to avoid damaging seal lip.
5. Install parking brake stop bolt and spring, torquing bolt to 8-9 ft. lbs.
6. Apply suitable grease to bore area around strut, then position parking brake strut into caliper bore.
7. Install new O-ring onto fast thread adjuster, then position adjuster in caliper bore.
8. Install key plate and snap ring. Ensure dimple on plate is properly positioned prior to installing snap ring.
9. Position snap ring compressor T87P-2588-B3 or equivalent into caliper bore, then insert washer, spring, spring retainer and snap ring into compressor.

Fig. 23 Rear Caliper Assembly Tools:

Fig. 24 Rear Caliper Brake Spring Compressor Tool Installation:

10. Position rear brake spring compressor T87P-2588-B or equivalent, Fig. 7, as shown in Fig. 8, and turn screw clockwise until snap ring is firmly seated.
11. Lubricate caliper body bore with clean hydraulic fluid, then install piston seal into groove.
12. Assemble piston assembly, then install new seal on adjuster nut.
13. Apply brake fluid to piston adjuster nut contact face, then install thrust bearing, thrust washers, wave washer and snap ring.
14. Install piston protective boot into caliper body groove. Stretch boot over piston, then start thread of adjuster nut on fast thread.
15. Screw piston onto fast thread adjuster using piston adjuster T87P-2588-A or equivalent, then compress into caliper base.
16. Secure piston protective cover into piston groove.
17. Apply suitable grease to slide pin bores and inside of boot, then install slide pins and slide pin bolts into anchor bracket. Secure protective boot in grooves.