Disassembly and Assembly

DISASSEMBLY
(1) Drain old brake fluid out of caliper into drain pan.

Piston Dust Boot:

(2) Remove piston dust boot. Use screwdriver to push boot out of groove.





(3) Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels. Towels will prevent piston damage when piston comes out of the caliper bore.
(4) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper.

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

WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS MAY RESULT IN PERSONAL INJURY.

Caliper Piston Seal:

(5) Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore.
(6) Remove caliper slide pin bushings and boots.
(7) Remove caliper bleed screw and cap.

ASSEMBLY
(1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper.
(2) Coat caliper piston bore, piston and new piston seal with clean brake fluid.

Fig 19 Installing Caliper Piston Seal:

(3) Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation.
(4) Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas.

Sliding Boot Onto Piston:

(5) Slide new seal boot over piston until boot lip seats in piston groove.

Snapping Boot Folds Into Place:

(6) Push retainer part of boot forward until folds in boot snap into place.

Installing Caliper Piston And Boot:

(7) Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore.
(8) Press caliper piston to bottom of bore.

Seating Piston Dust Boot:

(9) Seat piston dust boot with Installer 8248 and Handle C-4171.

Caliper Bleed Screw & Cap Installation:

(10) Install caliper bleed screw and bleed screw cap if removed.