Brake Caliper: Service and Repair

Fig. 2 Disassembled View Of A.T.E. Disc Brake:

DISASSEMBLY

1. Remove caliper assembly, refer to BRAKE PAD.
2. Place a wood block between caliper piston and caliper fingers. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss.
3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper.
4. Disconnect brake hose from caliper.
5. Mount caliper in a soft jawed vise.
6. Support caliper, then remove and discard dust boot.
7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. Do not use a screwdriver or other metal tool, as this may scratch caliper bore.
8. On all models except 1988 Dynasty, New Yorker and New Yorker Landau, remove caliper bushings. On 1988 Dynasty, New Yorker and New Yorker Landau, caliper bushing and sleeve assemblies are permanently sealed.

Fig. 3 Installing Piston Seal:

Installing Piston Into Caliper Bore:

ASSEMBLY

1. Mount caliper in a soft jawed vise.
2. Lubricate piston seal with clean brake fluid and install seal in caliper bore groove. Ensure seal is properly seated.
3. Lubricate piston boot with clean brake fluid and position over piston.
4. Install piston and boot assembly, pushing it past piston seal until it bottoms into caliper bore.
5. Using a hammer and tool No. C-4689 with C-4171 handle, drive dust boot into counterbore until properly seated.
6. On models where bushings require replacement, compress flanges of bushings and install on caliper housing. Ensure bushing flanges extend evenly over caliper housing on both sides. Remove Teflon sleeves from guide pin bushings prior to installing bushings in caliper. After bushings are installed in caliper, install Teflon sleeves in bushings.
7. On all models, connect brake hose to brake line at frame bracket.
8. Install caliper on vehicle, refer to BRAKE PAD.
9. Check brake fluid level of master cylinder reservoir, then open caliper bleed screw and bleed brake system until firm pedal is obtained.