Brake Caliper Overhaul - Front

IMPORTANT:
- Replace all the components included in the repair kit.
- Lubricate all of the rubber parts with clean brake fluid in order to ease assembly.
- Perform this overhaul procedure on a clean bench.

DISASSEMBLY PROCEDURE
1. Remove the brake caliper. Refer to Brake Caliper Replacement- Front.

CAUTION: 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) can fly out with force and could result in serious bodily injury.

NOTICE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.





2. Blow compressed air into the brake caliper hose hole in order to remove the brake caliper piston. The piston will come out through the piston boot.
3. Inspect and replace the brake caliper piston if any of the following conditions are found:
- Scoring
- Nicks
- Corrosion
- Worn or damaged chrome plating





4. Use a flat-bladed tool to remove the brake caliper piston boot (2). Do not 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.





5. Remove the piston seal (4) from the groove in the caliper bore (3). Use a small wooden or plastic tool.
6. Inspect the caliper bore (3) and the seal grooves for the following conditions:
- Scoring
- Nicks
- Corrosion
- Wear
7. Use a piece of crocus cloth in order to polish out light corrosion.
8. Replace the caliper housing (3) if corrosion in and around the seal groove cannot be cleaned with a piece of crocus cloth.





9. Inspect and replace any brake caliper bolt boots (4) that exhibit any of the following conditions:
- Cuts
- Tears
- Deterioration
10. Inspect the caliper bolts for corrosion or damage. If corrosion is found on the brake caliper bolt shaft, replace the brake caliper bolt (1), and the brake caliper bolt boot (4). Do not attempt to polish away the corrosion.
11. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged.





12. Remove the bleeder valve cap (1) and the bleeder valve (2) from the brake caliper housing (3).
13. Clean all the parts with clean, denatured alcohol.
14. Dry all the parts with filtered, non-lubricated compressed air.
15. Use filtered, non-lubricated compressed air in order to blow out all of the passages in the caliper housing and the bleeder valve.

ASSEMBLY PROCEDURE

- Tools Required
- J 36349 Dust Boot Seal Installer

NOTICE: Refer to Fastener Notice in Service Precautions.





1. Install the bleeder valve (2) and the bleeder valve cap (1) to the caliper housing (3).
- Tighten the bleeder valve (2) to 13 Nm (115 inch lbs.).
2. Install a new lubricated piston seal (4) to the caliper bore grooves. Ensure that the piston seal is not twisted.





3. Install the lubricated boot (1) onto the brake caliper piston (2).
4. Lubricate the brake caliper piston (2) with clean brake fluid.
5. Install the brake caliper piston and the brake caliper piston boot into the bore of the caliper. Push the brake caliper piston to the bottom of the bore.





6. Seat the caliper boot in the caliper housing (1) counterbore using the J 36349 Dust Boot Seal Installer.
7. Install the caliper. Refer to Brake Caliper Replacement- Front.