Disassembly and Assembly

Visually check caliper. If caliper housing is leaking, it should be replaced. If a seal is leaking, caliper must be disassembled and new seals and dust boot installed. If a piston is seized in the bore, replace caliper. Care must be taken when removing plastic piston.

DISASSEMBLY
1. Remove caliper from caliper mounting bracket.
2. Remove outer pad by slipping down caliper leg until clip is disengaged, then inner pad by pulling it straight out of piston.
3. Place a few shop towels between the caliper piston and caliper bridge. Do not place fingers between these areas. Two methods can be used to remove the piston from the caliper bore, one method is using low volume air pressure and the other is hydraulic pressure. If air pressure is not available, slowly apply the brake pedal until pedal drops to the floor. This method can only be done one caliper at a time. If air pressure is to be used, proceed as follows:
a. Disconnect the flexible hose from caliper assembly, then remove caliper from vehicle.
b. Using a air nozzle, lightly apply air pressure to brake hose inlet until piston is free from caliper.

WARNING: Do not use shop pressure if it cannot be adjusted down to a safe level (15-30 psi) or personal injury and/or damage to components could result.

4. Remove seal and dust boot from caliper assembly.

CLEANING & INSPECTION
Clean all metal parts with isopropyl alcohol. Then clean out and dry grooves and passage ways with compressed air. Ensure caliper bore and component parts are cleaned thoroughly. Check cylinder bore and piston for damage or excessive wear. Examine piston for surface irregularities or small chips and cracks. Minor surface imperfections are allowable, provided they do not enter the dust boot groove area. Replace piston if damaged.

ASSEMBLY
1. Coat new seal with clean brake fluid, then install in caliper assembly.
2. Coat dust boot with clean brake fluid, then install in caliper assembly.
3. Coat piston with clean brake fluid, then place piston in caliper assembly and push firmly into caliper bore.
4. With piston seated, completely seat piston using a 4 inch C-clamp and a block of wood approximately 2 3/4 inch x 1 inch x 3/4 inch thick.
5. Ensure that dust boot is tight in boot groove on piston and in caliper.
6. Install brake pads, then caliper.