Disassembly and Assembly

DISASSEMBLY
1. Drain the brake fluid from caliper.

C-Clamp One Piston:

2. C-clamp a block of wood over one piston.

Protect Caliper Piston:

3. Take another piece of wood and pad it with one-inch thickness of shop towels. Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal.
4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.

CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston.

WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury.

5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore.
6. Move the padded piece of wood in front of the other piston.
7. Remove the second piston using the same procedure with short bursts of low pressure air.

Piston Dust Boot Removal:

8. Remove piston dust boots with a suitable pry tool.

Piston Seal:

9. Remove piston seals from caliper.

CAUTION: Do not scratch piston bore while removing the seals.

Disc Brake Caliper:

10. Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper.
11. Remove caliper bleed screw.

ASSEMBLY

CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.

1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid.

Piston Seal:

2. Install new piston seals into caliper bores.

NOTE: Verify seal is fully seated and not twisted.

3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston.
4. Stretch boot rearward to straighten boot folds, then move boot forward until folds snap into place.

Caliper Piston Installation:

5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle.

Seating Dust Boot:

6. Seat dust boot in caliper with Handle C-4171 or equivalent and Installer:
- HD 56 mm caliper: Installer C-4340
- LD 54 mm caliper: Installer C-3716-A
7. Install the second piston and dust boot.
8. Lubricate caliper mounting bolt bushings, boot seals and bores with silicone grease.
9. Install the boot seals into the caliper seal bores and center the seals in the bores.
10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing groves at either end of the bushing.
11. Install caliper bleed screw.