Rampage L4-135 2.2L (1983)
Brake Caliper: Service and Repair
ATE Floating Caliper
Fig. 2 Typical exploded view of disc brake caliper assembly
DISASSEMBLE
1. Remove caliper assembly as described under "Brake Shoe & Lining, Replace."
2. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first
inch of brake pedal travel to prevent brake fluid loss.
3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat
procedure to remove piston from other caliper. Air pressure should never be used to remove piston from bore.
4. Disconnect brake hose from caliper.
5. Mount caliper, in a soft jawed vise.
6. Support caliper and remove dust boot and discard.
7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard.
8. Using a suitable tool, remove bushings from caliper.
INSPECTION
1. Clean all components using alcohol or other suitable cleaning solvent, then blow dry using compressed air. With compressed air blow out drilled
passages and bores.
2. Inspect piston bore for pitting or scoring. Light scratches or corrosion can usually be cleared with crocus cloth. Bores that have deep scratches or
scoring should be honed with tool No. C-4095, providing bore diameter is not increased by more than 0.001 inch. If scratches or scoring cannot be
cleared up, or if caliper bore is increased by more than 0.001 in., replace caliper housing. When using hone C-4095, coat hone and caliper bore
with clean brake fluid. After honing, carefully clean boot and seal grooves with a stiff non-metallic brush. Flush caliper with clean brake
fluid and wipe dry with a clean lint free cloth, then flush and wipe caliper dry again.
3. Replace piston if found to be scored, pitted or if plating is severely worn or if caliper bore was honed. Black stains on steel piston are caused by
piston seal and are not cause for replacing piston.
Fig. 2 Typical exploded view of disc brake caliper assembly
