Front Brake Caliper Overhaul
Disassembly Procedure
Warning: Refer to
Brake Dust Warning .
Warning: Refer to
Brake Fluid Irritant Warning .
|
Warning:
Do not place fingers in front of the caliper
piston(s) in an attempt to catch or protect it when applying
compressed air. The piston(s) can fly out with force and could
result in serious bodily injury. |
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Caution: Use clean cloths to pad interior of caliper housing
during piston removal. Use just enough air to ease the pistons out
of the bores. If the pistons are blown out, even with the padding
provided, it may be damaged. |
| 2. |
Remove the brake caliper
piston from the caliper bore by directing low pressure compressed
air into the caliper (1) through the fluid inlet hole. |
| 3. |
Remove the piston dust boot
seal (1) from the seal counterbore in the caliper (4). Discard the
boot seal. |
| 4. |
Using a small wooden or
plastic tool, remove the piston seal (3) from the caliper bore.
Discard the piston seal. |
| 5. |
Remove the bleeder valve cap
(6). |
| 6. |
Remove the bleeder valve
(5). |
|
Note: Do not use
abrasives to clean the brake caliper piston.
|
| 7. |
If cracks, scoring, pitting,
excessive rust, and/or excessive corrosion are present in the
caliper bore, replace the caliper assembly. |
| 8. |
If light rust or light
corrosion are present in the caliper bore, attempt to remove the
imperfection with a fine emery paper. If the imperfection cannot be
removed, replace the caliper assembly. |
| 9. |
Clean the brake caliper piston
bore and seal counterbore, and the caliper piston with denatured
alcohol, or equivalent. |
| 10. |
Dry the caliper piston bore
and counterbore, and the piston with non-lubricated, filtered,
compressed air. |
| 11. |
Inspect the caliper piston for
cracks, scoring, and/or damage to the plating. Replace the caliper
piston if any of these conditions exist. |
| 12. |
Inspect the caliper mounting
holes for cracks, scoring, pitting, rust and/or excessive
corrosion. Replace the caliper assembly if any of these conditions
exist. |
Assembly Procedure
| 2. |
Install the lubricated, new
piston seal (3) into the caliper bore. |
| 4. |
Install the bottom half of the
caliper piston (2) into the caliper bore. |
| 5. |
Install the new piston dust
boot seal (1) over the caliper piston (2). |
| 6. |
Compress the caliper piston
(2) to the bottom of the caliper bore. |
| 7. |
Fully seat the piston dust
boot seal (1) into caliper counterbore. |
| 8. |
Install the bleeder valve to
the caliper and tighten the valve to 17 N·m (13 lb
ft) . |
| 9. |
Install the bleeder valve
cap. |
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