Rear Caliper Overhaul

DISASSEMBLE
1. Caliper. Rear Caliper Replacement

WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) may come out with force resulting in serious injury.

Removing Piston:

2. Piston using pressure compressed air into the caliper inlet hole. Piston will come out through piston boots. An alternate method for piston removal is to use spanner-type tool in slots in end of piston to thread piston of caliper.

Removing Boot Ring:

3. Boot ring and piston boot. Use small screwdriver to pry up one end of boot ring. Work boot ring out of caliper groove.
4. Piston seal from groove in caliper. Use a small wooden or plastic tool (not metal) to start piston seal out of caliper bore groove.
5. Bleeder valve and bleeder cap valve.

Remove Return Spring:

6. Lever return spring only if replacement is required. Use screwdriver to disengage return spring from parking brake lever. Then, unhook spring from stopper pin.
7. Pin boot and bolt boot from caliper
8. Bolt sleeve and sleeve boot from caliper support.
9. Pin bolt and pin sleeve from caliper support. Clean all parts in clean, denatured alcohol. Dry with unlubricated, low, pressure compressed air. Blow out, all passages, in caliper and bleeder valve.

NOTE: Inspect piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found. Inspect piston bore for scoring nicks, wear or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace caliper. Do not hone caliper bore. Seal groove in caliper bore for nicks or burrs. If found replace caliper. Inspect boots for cuts, tear's or deterioration. If damaged, replace boots. Inspect bolt sleeve and pin sleeve for corrosion or damage. Replace corroded or damaged sleeves. Do not attempt to polish away corrosion.

ASSEMBLE
1. Pin bolt and pin sleeve to caliper support. Tighten torque bolt to 27 Nm (20 ft. lbs.). Lubricate pin sleeve OD with silicone grease.
2. Compress lip sleeve boot and push it all the way through caliper until lip emerges and seats on inboard face of caliper ear. Lubricate sleeve boot with silicone grease to ease assembly.
3. Push bolt sleeve in through lip end of boot until boot seats in sleeve groove at other end. Lubricate sleeve OD with silicone grease to ease assembly.
4. Bolt boot onto caliper.
5. Pin boot over pin sleeve (installed on caliper support). Install small end of boot over pin sleeve until boot seats in pin groove.
6. New lever return spring if replaced. Position spring with hook end around stopper pin, then pry other end or spring over lever.
7. Bleeder valve. Tighten valve to 11 Nm (97 inch lbs.).
8. Bleeder valve cap.
9. New piston seal. Lubricate seal with clean brake fluid. Make sure seal is not twisted.
10. Piston boot onto piston.

Caliper Piston Installation:

11. Piston and boot into bore of caliper. Lubricate piston OD with clean brake fluid. Start piston in by hand, then threads into bottom of caliper bore using spanner-type tool in slots in end of piston.
12. Boot ring.
a. Mark sure outside edge of piston boot is smoothly seated in counterbore of caliper.
b. Work boot ring into groove near open end of caliper bore using care not to pinch piston boot between boot ring and caliper.
c. After installing ring, lift inner edge of boot next to piston and press out any trapped air. Boot must lay flat.
13. Caliper. Rear Caliper Replacement