Disassembly and Reassembly
Disassembly Procedure1. Remove the caliper.
2. To prevent damage to the piston when removing it, place a clean shop towel between the piston and the caliper.
WARNING: When applying air pressure at the caliper inlet port, do not place fingers in front of the piston. The piston will pop out of its bore with enough force to cause serious injury.
3. Apply unlubricated compressed air to the caliper inlet port, and progressively increase the air pressure until the piston is forced out of the bore.
4. Remove and discard the outer dust seal.
5. Remove the inner seal and discard it. Do not scratch the piston bore or the seal groove when removing the inner seal.
6. Remove the bleeder valve and the dust cover.
Assembly Procedure
WARNING: Keep alcohol and brake fluid away from the eyes, as serious injury may result
CAUTION: Keep rubber seals and brake parts away from oil. Oil can cause the seals to swell and deteriorate, and the braking system could become inoperative.
Important: Do not use a hone or any other procedure to remove material from the piston or caliper bore.
1. Clean all parts with denatured alcohol or brake fluid. Dry the parts with unlubricated compressed air, and blow out all passages in the caliper and the bleeder valve.
2. Inspect the piston and the caliper for scoring and corrosion. Replace any components that show these conditions.
3. Insert the bleeder valve and the dust cover.
Tighten
Tighten the bleeder valve to 11 Nm (97 inch lbs.).
4. Lubricate the new inner seal and the caliper bore with brake fluid.
5. Install the inner seal into the groove in the caliper bore.
6. Install the outer seal into the caliper bore.
7. Lubricate the piston with brake fluid.
8. Install the piston into the caliper.
9. Install the outer seal into the piston groove. Apply steady hand pressure until the piston is seated in the bore.
10. Inspect the brake shoe linings for minimum thickness. If necessary, install new shoes.
11. Inspect the guide pins and boots. If the boots are damaged, or if the guide pins do not slide easily, replace these parts. Lubricate the guide pins with a lithium soap base glycol grease or other grease which will not deteriorate or swell the rubber boots.
12. Install the caliper.