Brake Caliper Overhaul

REMOVAL PROCEDURE

^ Tools Required
- J 26267 Dust Boot Seal Installer.





1. Remove the caliper from the vehicle.
2. Remove the bushings.

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.

3. Inspect the bushings for nicks and cuts. Replace the bushings if damaged.
4. Use clean shop towels to pad the interior of the caliper during piston removal.





5. Remove the piston using compressed air into the caliper inlet hole.
6. Inspect the piston for scoring, nicks, corrosion, and worn or damaged chrome plating. Replace the piston if any of these are found.
7. Remove the boot. Be careful not to scratch the housing bore.
8. Remove the piston seal from the seal groove in the caliper bore using a small plastic or wood tool. Do not use a metal tool because this may damage the caliper bore or seal groove.
9. Inspect the caliber bore and seal groove for scoring, nicks, corrosion and wear.
10. Use a crocus cloth to polish out light corrosion. Replace the caliper housing if corrosion in and around the seal groove will not clean off with a crocus cloth.
11. Remove the bleeder valve cap.
12. Remove the bleeder valve from the caliper.
13. Clean all parts in clean, denatured alcohol.
14. Dry the parts with Unlubricated compressed air.
15. Blow out all passages in the caliper housing and bleeder valve.

INSTALLATION PROCEDURE
1. Install the bleeder valve.

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

2. Install the bleeder valve cap.
^ Tighten Bleeder valve cap to 13 Nm (110 inch lbs.).

3. Install the lubricated new piston seal into the caliper bore groove. Make sure the seal is not twisted.
4. Install the lubricated boot into the bore of the caliper. Push the piston to the bottom of the bore.





5. Using the J 26267, seat the boot in the caliper housing.
6. Install the bushings.
6.1. Lubricate the beveled end of the bushing with silicone grease.
6.2. Pinch the bushing and install the beveled end first.
6.3. Push the bushing through the housing mounting bore.
7. Install the caliper into the vehicle.