CALIPER (REAR) DISASSEMBLY/ASSEMBLY

id041100800600

1.  Remove the brake caliper. (See REAR BRAKE (DISC) REMOVAL/INSTALLATION.)

2.  Secure the brake caliper in a vise.

3.  Disassemble in the order indicated in the table.

atraaw00001773

1	Bleeder cap
2	Bleeder screw
3	Piston (See Piston Disassembly Note.)
4	Dust seal (See Dust Seal Assembly Note.)
5	Piston seal (See Piston Seal Disassembly Note.) (See Piston Seal Assembly Note.)
6	Caliper body

4.  Assemble in the reverse order of disassembly.

Note

•  Inspect the piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new piston must be installed.

Piston Disassembly Note

1.  Remove the piston.

(1)  Place a block of wood between the brake caliper piston and the brake caliper housing.

atraaw00001774

(2)  Apply compressed air through the caliper bleeder screw port to remove the piston.

Warning

•  When compressed air is blown into the caliper body, injury to a finger or other part from pinching could result from the piston springing up. When blowing in compressed air, do not place your fingers between the piston and caliper body when performing the work.

Caution

•  The piston could be damaged if blown out with great force. Blow the compressed air slowly to prevent the piston from suddenly popping out.

Piston Seal Disassembly Note

1.  Remove the piston seal using a plastic or wooden tool.

Caution

•  Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak.

Piston Seal Assembly Note

1.  Lubricate the piston seal with clean brake fluid.

2.  Assembly the piston seal.

Dust Seal Assembly Note

1.  Assemble a new dust seal to the caliper using the SSTs and a press.

atraaw00002456

Caution

•  Assemble the dust seal to the caliper based on the dust seal press-in value, otherwise the dust seal may be deformed.

2.  Verify that there is no deformation or damage on the dust seal, or gaps between the dust seal and caliper body.

Piston Assembly Note

1.  Press the piston into the dust seal opening as shown in the figure.

atraaw00001776

2.  Insert a piece of wood between the caliper body and the piston, and while supporting the piston by hand, blow compressed air through the brake hose installation hole.

atraaw00001777

Warning

•  When blowing compressed air into the caliper body, the piston may pop out and cause injury if not supported at the correct point. Securely support the piston friction surface by hand when blowing compressed air.

Note

•  By blowing compressed air, the dust seal expands due to air pressure and covers the piston end.

3.  Verify that the dust seal lip covers the piston end as shown in the figure.

atraaw00001778

4.  Press the piston into the caliper body completely.