Brake Caliper Overhaul

Disassembly Procedure





1. Remove the caliper from the vehicle. Refer to Brake Caliper Replacement.

Caution: Wear safety glasses in order to avoid eye damage.

Caution: Do not place fingers in front of the piston in an attempt to catch or protect the piston when applying compressed air to the caliper brake hose connector hole. Serious injury could result. Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the block of wood in place, damage may occur.

2. Insert a block of hard wood or a shop cloth into the caliper interior to catch the piston as it is forced out of the bore with compressed air.
3. Remove the piston from the caliper by applying compressed air to the caliper brake hose connector hole.





4. Remove the piston sea] (1) from the caliper (2) using a thin, bladed tool.
5. Remove the bleeder valve and cap from the caliper.
6. Clean the caliper slide bushing, the caliper set ring, the piston, caliper carrier, and caliper housing in clean brake fluid.
7. Dry the parts with non-lubricated, compressed air.
8. Blow out all of the passages in the caliper housing and bleeder valve.
9. Inspect the piston for scoring, corrosion, and any damage to the chrome plating. Replace the piston if any of these conditions are observed.
10. Inspect the caliper bore for scoring, pitting, and corrosion. Use a crocus cloth to polish out any light corrosion. If the corrosion cannot be removed, replace the caliper.

Assembly Procedure





1. Lubricate the piston seal and boot with clean brake fluid.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the bleeder valve and cap to the caliper.
- Tighten the bleeder valve to 10 Nm (89 lb in).
3. Install the new piston seal into the groove on the caliper housing. Make sure the seal is not twisted.
4. Install the new boot to the piston.
5. Fit the boot (2) into the caliper groove and cylinder (1) with fingers.
6. Insert the piston into the cylinder by hand and fit the boot inside the piston groove.
7. To confirm that the boot is fitted, pull the piston out of the cylinder a little, but do not remove it.
8. Push the piston fully into the cylinder by hand.
9. Install the caliper to the vehicle. Refer to Brake Caliper Replacement.