Disassembling and Assembling

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 prebled.
^ Apply a thin coat of grease G 052 150 A2 to brake cylinders, pistons and seals.
^ When repairing, be sure to prebleed brake calipers (without brake pads) before installing.

1 - Self - locking bolt
^ Tighten to 30 Nm (22 ft. lbs.)
^ Always replace
^ When loosening and tightening, counterhold on guide pin
2 - Bleeder screw
^ Apply thin coat of grease G 052 150 A2 to threads before installing
3 - Dust cap
4 - Guide pins
^ Apply thin coat of grease G 052150 A2 before pulling on protective cap
5 - Protective cap
^ Pull onto brake carrier and guide pin
6 - Brake carrier with guide pin and protective cap
^ Replacement part is assembled with sufficient grease on guide pins.
^ If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins.
7 - Dust boot
^ Pull outer sealing lip onto piston
8 - Piston with - automatic adjustment
^ Apply thin coat of brake fluid to piston before inserting
9 - Piston seal
10 - Brake caliper housing with parking brake cable lever
^ If leaking at parking brake cable lever, replace brake caliper housing
^ After repairing, prebleed caliper housing.

Special tools and equipment





^ 3272 Piston resetting and removal tool





^ 3409 Wedge
^ Bleeder bottle

Removing





^ Remove piston from brake caliper housing by turning knurled wheel counterclockwise.

Notes:
^ Install special tool 3272 with the collar (arrow) positioned before the piston.
^ If the piston is difficult to move, use a 13 mm wrench on the flats (arrow -A-).





^ Remove seal using wedge 3409.

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

Installing
^ Apply thin coat of brake fluid on piston and piston seal.
^ Install piston seal in caliper housing.





^ Place dust boot with outer sealing lip on piston.





^ Hold piston in front of caliper housing and install inner sealing lip into grove in cylinder using wedge 3409.





^ Screw piston into housing by turning knurled wheel clockwise.

Notes:
^ Install special tool 3272 with the collar (arrow) of the tool seated on the brake caliper.
^ If the piston is difficult to move, use a 13 mm wrench on the flats (arrow - A-) .
^ If the piston is pushed back with the piston resetting tool or by operating the foot brake, the automatic adjustment in the brake caliper is destroyed.

^ Install brake pads.

Brake caliper, pre-bleeding





^ Open bleeder screw (arrow -A-) and fill a standard bleeder bottle with brake fluid until bubble-free fluid flows from brake hose connection (arrow -B-).
^ Close bleeder screw.