Removal and Installation

REMOVAL
1. Remove the wheel and tire.
2. Disconnect the brake hose.

NOTE: Plug the brake hose, so brake fluid does not run out.

3. Remove the cylinder mounting bolt.
4. Remove cylinder and pads.
5. Remove the caliper mounting bolts (2EA) from knuckle.





6. Remove the carrier.

DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.





NOTE:
1. Do not place fingers in front of the piston when using compressed air.
2. Be careful not to splatter the brake fluid.





3. Remove the piston seal from the caliper using a screwdriver.

INSPECTION
1. Check the caliper for wear, damage, cracks and rust.
2. Check the piston for rust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and rust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, rust, wear and cracks.

CAUTION:
1. Do not use sand paper on the piston surface.
2. All rubber parts must be replaced with new parts.





6. Inspect the disc using a calipers and dial gauge.





7. If necessary, replace the brake disc.

ASSEMBLY
1. Clean all components with isopropyl alcohol except the pads and shims.





2. Apply rubber grease to the piston seal and install the piston seal in the cylinder.





3. Assemble the piston and piston boots according to the following procedure.
1. Apply rubber grease to the caliper bore, the out side surface of the piston and the piston boot.
2. Install the piston boot on the piston as illustrated.
3. Insert the piston boot in the inner groove of the caliper and slide the piston into the caliper.





4. Assemble the sliding parts according to the following procedure.
1. Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot and sleeve boot.
2. Insert the boots into the groove of the caliper.





5. Install the pads.

NOTE: Do not apply grease to the disc or pads.





6. Tighten the brake hose connecting bolt.





NOTE:
1. Check that the surface of the pin and bolts are not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting parts.