Brake Caliper: Service and Repair
FRONT1. Raise and support vehicle, then remove front wheel.
2. Drain a moderate amount of brake fluid from reservoir with a syringe.
3. Disconnect caliper brake hose.
4. Remove caliper bolts and disconnect brake pad wear sensor electrical connector, if necessary.
5. Remove caliper toward rear.
6. Reverse procedure to install, noting the following:
a. Tighten bolts to specifications.
b. Bleed brake system.
c. Ensure brake pad wear sensor wire does not contact rotor or wheel.
REAR
1. Raise and support vehicle, then remove wheel.
2. Drain a moderate amount of brake fluid from reservoir with a syringe.
3. Disconnect and plug caliper hydraulic line.
4. Disconnect brake pad wear sensor, then remove caliper.
5. Reverse procedure to install. Tighten bolts to specifications and bleed brake system.
OVERHAUL
Fig. 7 Guide bolt dowel sleeve installation:
1. Remove piston boot and snap ring.
2. Position block of wood in caliper recess, then apply compressed air to fluid inlet to force piston from bore.
3. Remove bleeder screw.
4. Remove piston seal using a suitable tool, taking care not to damage caliper bore.
5. Remove dowel sleeves (5) from guide bolt bores, Fig. 2.
6. Clean caliper and piston with alcohol, blow dry with compressed air and coat sealing surfaces with brake fluid.
7. Inspect piston and replace if corroded, or if sealing surface is worn or damaged.
8. Inspect caliper body and replace if sealing grooves are worn or corroded, or if caliper is damaged or distorted. Do not machine inner bore of caliper.
9. Coat new piston seal with brake fluid and seat seal in caliper bore groove.
10. Install dust boot on piston, then seat piston in caliper bore, ensuring piston enters bore straight.
11. Seat dust boot in groove, then install retaining ring.
12. Install guide bolt dowel sleeves.
13. Ensure bleeder valve is clear, then install valve.