Overhaul

REMOVAL PROCEDURE

CAUTION: When servicing brake parts, do not create dust by grinding or sanding brake linings, by cleaning brake parts with a dry brush or with compressed air. Many earlier models or aftermarket brake parts may contain asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts. Equipment is commercially available to perform this washing function. These wet methods will prevent fibers from becoming airborne.





1. Remove the caliper completely from vehicle.
Refer to Brake Caliper Replacement.
2. Remove the bushing.
3. Inspect the bushings for cuts and nicks.
Replace the bushings if damage is evident.

CAUTION: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

IMPORTANT: Use clean shop towels in order to pad the interior of the caliper housing during removal.





4. Remove the piston using compressed air into the caliper inlet hole (3).
5. Inspect the piston for the following conditions. Replace the piston if any of the following conditions are found:
- Scoring
- Nicks
- Corrosion
- Worn or damaged chrome plating

6. Remove the boot from the caliper housing bore
Be careful not to scratch the housing bore.

NOTICE: do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result.





7. Remove the piston seal (1) from the seal groove in the caliper housing bore using a small wood or plastic tool.
- Inspect the caliper housing bore and the seal groove for scoring, nicks, corrosion and wear.
- Use a crocus cloth in order to polish out light corrosion.
- Replace the caliper housing if corrosion in and around the seal groove will not clean up with a crocus cloth.





8. Remove the bleeder valve (2) and the bleeder valve cap from the caliper (1).
- Clean all parts in clean, denatured alcohol.
- Dry the parts using non-lubricated compressed air.
- Blow out all passages in the caliper housing and the bleeder valve.

INSTALLATION PROCEDURE

NOTICE: Refer to Fastener Notice in Cautions Notices.





1. Assemble the bleeder valve (2) and the bleeder valve cap into the caliper (1).
- Tighten the bleeder valve to 13 Nm (115 in. lbs.).





2. Lubricate the new piston seal (3).
3. Install the new piston seal (3) into the caliper bore groove. Ensure that the seal is not twisted.
4. Install the lubricated boot (5) onto the piston.
5. Install the piston (4) and boot (5) into the bore of the caliper (1). Push the piston (4) and the boot (5) to the bottom of the bore.
6. Seat the boot (5) in the caliper housing counter bore.





7. Install the guide pin assemblies (10).
- Lubricate the guide pins (10) and caliper bores with silicone grease, or equivalent.
- Ensure rubber guide pin boots are installed and seated.
- Wipe any excess grease from outside of seals.

8. Install the caliper (13).