Caliper Overhaul

Caliper Assembly:

1. Remove shoe retainer spring (14) from end of piston (17) by rotating retainer until inside tabs line up with notches in piston.
2. Remove nut (1) and lever (2).
3. Remove lever seal (6) and anti-friction washer (7).
4. Use clean shop towels to pad the interior of the caliper (25) during removal.

Removing Piston From Caliper:

5. Remove piston (17). Use a wrench to rotate actuator screw to work piston out of caliper. Rotate in parking brake apply direction.

INSPECT
^ Piston (17) for scoring, nicks, corrosion and worn or damaged chrome plating. Replace piston if any of these conditions are found.
6. Remove balance spring (20).
7. Remove actuator screw (19) by pressing on thread end.
8. Remove shaft seal (22) and thrust washer (21) from actuator screw (19).

CAUTION: Do not use a metal tool to remove piston seal in step 10. This may damage caliper bore or seal groove.

Removing Boot:

9. Remove boot (15), being careful not to scratch the housing (25) bore.
10. Remove piston seal (18) using wooden or plastic tool so as not to damage caliper (25) bore.
11. Remove protector (23) and bleeder valve (24). Remove bracket (5) only if damaged.

INSPECT
^ Caliper housing bore and seal groove for scoring, nicks, corrosion and wear.

12. Use crocus cloth to polish out light corrosion. Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth.
13. Clean all parts in clean, denatured alcohol. Dry with unlubricated compressed air. Blow out all passages in housing (25) and bleeder valve (24).

ASSEMBLY
1. Install bleeder valve (24).
2. Install protector (23) on bleeder valve (24).
3. Install bracket (5), if removed, with bolt (4) to 33-52 Nm (24-38 lb. ft.).
4. Lubricate all rubber parts with clean brake fluid prior to installation.
5. Install new piston seal (18) into caliper (25) bore groove. Make sure seal is not twisted.
6. Install lubricated boot (15) onto piston (17) with inside lip of boot in piston groove and boot fold toward end of piston that contacts inboard brake shoe
7. Install thrust washer (21) on actuator screw (19) with copper side of washer towards the piston assembly and the grayish surface towards caliper housing (25).
8. Install lubricated shaft seal (22) on actuator screw (19).
9. Install lubricated actuator screw (19) in piston (17).
10. Install balance spring into piston (17) recess.
11. Install lubricated piston (17) with actuator screw assembly, balance spring and boot into lubricated bore of caliper (25). Push piston to bottom of caliper bore using.
12. Install lubricated anti-friction washer (7) and lever seal (6) over end of actuator screw (19). Sealing bead on lever seal should be against housing (25).
13. Install lever (2) on actuator screw (19). Rotate lever away from stop slightly and hold while installing nut (1) to 41-54 Nm (30-40 lb. ft.), then rotate lever back to contact stop.
14. Install seat boot (15) in caliper housing (25) counterbore.
15. Install retainer spring (14) in groove in end of piston (17).
16. Align inside retainer tabs with piston notches. Rotate retainer so that tabs enter piston groove.
17. Install caliper.