Cirrus V6-2.5L VIN H (1995)
Brake Caliper: Service and Repair
Disassembly and Assembly
1. Remove caliper from brake rotor and brake pads from caliper as described in Brake Pad/Service and Repair.
2. Hang caliper on a wire away from rotor.
3. Place a small piece of wood between piston and caliper fingers.
4. Carefully depress brake pedal to hydraulically push piston out of bore, then apply and hold down brake pedal to any position beyond the first inch
of brake travel. This will prevent master cylinder brake fluid loss.
5. Disconnect brake line from caliper. Plug brake line to avoid any additional brake fluid loss.
6. Mount brake caliper assembly in soft jawed vise.
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
7. Remove guide pin bushings from caliper.
8. Remove piston dust boot from caliper and discard.
9. Using a plastic trim stick, work piston seal out of its groove in caliper piston bore. Do not use a screw driver or other metal tool for this
operation, because of the possibility of scratching piston bore or burring edges of seal groove.
10. Clean all parts using alcohol or a suitable solvent and wipe dry using a lint free cloth. No lint residue can be left in the caliper bore.
11. Inspect piston bore for scoring or pitting. Light scratches or corrosion can usually be cleared from the bores using crocus cloth. Bores that show
deep scratches or scoring should be honed. Bore diameter should not be honed more than 0.001 inch. If bore does not clean up within this
specification, a new caliper housing should be installed.
12. When honing brake caliper housing, coat stones and bore with brake fluid.
13. After honing bore, clean seal and boot grooves with a stiff non-metallic rotary brush.
CAUTION: Use extreme care in cleaning caliper after honing. Remove all dirt and grit by flushing caliper with brake fluid, wipe dry with a lint
free cloth.
14. Replace caliper piston if there is any pitting, scratches, or physical damage.
15. Dip new piston seal in clean brake fluid and install in caliper bore groove. Seal should be positioned at one area in groove and gently worked
around the groove, using only your fingers until properly seated. Never reuse old piston seal.
16. Coat new piston boot with clean brake fluid leaving a generous amount inside boot.
17. Coat dust boot with clean brake fluid, the position over piston.
18. Install piston into caliper bore pushing it past piston seal until it bottoms in caliper bore.
19. Position dust boot in counterbore of caliper piston bore.
20. Using a hammer and piston caliper boot installer tool No. C-4689 and handle tool No. C-4171, or their equivalents, drive boot into counterbore of
the caliper.
21. Install guide pin bushings and dust boots.
22. Attach hydraulic brake line to caliper. Always use new seal washers when installing brake line to caliper.
