FN 3 Front Brake Calipers

Overview





CAUTION! Before working on the brake system, read CAUTIONS and WARNINGS.

Notes:
^ Install all parts in repair kit.
^ New brake calipers are filled with brake fluid and are prebled.
^ When assembling, apply a thin coat of grease G 052 150 A2 to brake cylinders, pistons and seals.
1 - Dust cap
2 - Bleeder valve
^ Apply thin coat of brake fluid to threads before installing.
3 - Cap
^ Insert in mounting bushing
4 - Guide pin
^ Tighten to 25 Nm (18 ft. lbs.)
5 - Mounting bushing
^ Insert into brake caliper housing
6 - Brake caliper housing
7 - Brake carrier
8 - Retaining spring
^ Insert with both ends in holes in brake caliper housing
9 - Piston seal
10 - Piston
^ Apply thin coat of brake fluid to piston before inserting
^ Piston diameter: 54 mm (2.125 inch lbs.
11 - Dust boot
^ Do not damage when inserting piston

Special tools and equipment





^ 3409 Wedge
^ Piston resetting tool

Removing





^ Force piston out of brake caliper housing using compressed air.

CAUTION!
^ Place a piece of wood in the recess to prevent damaging the piston.
^ Use only enough air pressure to force piston out.

WARNING! Always wear safety goggles when working with compressed air.





^ Remove seal using wedge 3409.

CAUTION! When removing, use care to ensure that the cylinder bore is not damaged.

Installing
^ Install new piston seal in caliper.
^ Lubricate piston and cylinder bore lightly using grease G 052 150 A2.





^ Install dust boot with outer sealing lip on piston.





^ Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409.





^ Press piston into brake caliper housing using piston resetting tool.
^ The outer sealing lip of the dust boot must slip into the piston groove.