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Diagnosis and repair



DISASSEMBLY

{tag}1135688454@


1.Drain the fluid from the cylinders.

2.Secure the caliper assembly in a vise.

{tag}1136168891@


3.Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block.

4.Remove the wood block, and remove the pistons.

5.Remove and discard the piston seals and boots.

6.If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.

CLEANING and INSPECTION

Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean.

Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing.

NOTE: Do not use a wire brush in the cylinder bore.

Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face.

Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly.

Replace the anti-rattle clip, piston seal and dust boot with new components.

ASSEMBLY

NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled.

1.Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores.

2.Apply a film of clean brake fluid to the cylinder bores.

3.Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores.

4.Apply a film of clean brake fluid to the pistons.

5.Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal.

6.Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated.

7.Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins.

DISASSEMBLY

Disc Brake Caliper DisassembledDisc Brake Caliper Disassembled



1.Drain the fluid from the cylinders.

2.Secure the caliper assembly in a vise.

{tag}1136168891@


3.Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block.

4.Remove the wood block, and remove the pistons.

5.Remove and discard the piston seals and boots.

6.If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.

CLEANING and INSPECTION

Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean.

Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing.

NOTE: Do not use a wire brush in the cylinder bore.

Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face.

Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly.

Replace the anti-rattle clip, piston seal and dust boot with new components.

ASSEMBLY

NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled.

1.Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores.

2.Apply a film of clean brake fluid to the cylinder bores.

3.Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores.

4.Apply a film of clean brake fluid to the pistons.

5.Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal.

6.Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated.

7.Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins.

DISASSEMBLY

{tag}1135688454@


1.Drain the fluid from the cylinders.

2.Secure the caliper assembly in a vise.

Removing Caliper PistonRemoving Caliper Piston



3.Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block.

4.Remove the wood block, and remove the pistons.

5.Remove and discard the piston seals and boots.

6.If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.

CLEANING and INSPECTION

Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean.

Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing.

NOTE: Do not use a wire brush in the cylinder bore.

Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face.

Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly.

Replace the anti-rattle clip, piston seal and dust boot with new components.

ASSEMBLY

NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled.

1.Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores.

2.Apply a film of clean brake fluid to the cylinder bores.

3.Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores.

4.Apply a film of clean brake fluid to the pistons.

5.Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal.

6.Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated.

7.Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins.

DISASSEMBLY

Disc Brake Caliper DisassembledDisc Brake Caliper Disassembled



1.Drain the fluid from the cylinders.

2.Secure the caliper assembly in a vise.

Removing Caliper PistonRemoving Caliper Piston



3.Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block.

4.Remove the wood block, and remove the pistons.

5.Remove and discard the piston seals and boots.

6.If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.

CLEANING and INSPECTION

Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean.

Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing.

NOTE: Do not use a wire brush in the cylinder bore.

Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face.

Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly.

Replace the anti-rattle clip, piston seal and dust boot with new components.

ASSEMBLY

NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled.

1.Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores.

2.Apply a film of clean brake fluid to the cylinder bores.

3.Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores.

4.Apply a film of clean brake fluid to the pistons.

5.Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal.

6.Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated.

7.Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins.




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