Brake Caliper: Service and Repair

FRONT DISC BRAKE





COMPONENTS

DISASSEMBLY
1. Loosen the bleeder screw and drain the brake fluid out of the caliper. Install the bleeder screw.





2. Remove the piston boot.





3. Position a block of wood or a roll of shop towels between the piston and the caliper.

WARNING: NOT USE AN EXCESSIVE AMOUNT OF AIR PRESSURE TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE CALIPER BORE.

NOTE: A compressed air can be used as an alternative to removing the caliper piston. Apply the air pressure through the fluid inlet port. Apply only enough pressure to ease the piston out of the bore.

4. Remove the piston.





5. Remove the piston seal from the caliper bore. Use a plastic or wooden stick to remove the seal.
6. Remove the bleeder screw.
7. Remove the bushing and the pin bolts.

CAUTION: Do not use petroleum based solvent, kerosene, or gasoline for cleaning caliper parts. Their use as a cleaning agent can leave residues which can damage the rubber seals.

8. Wash the parts in clean denatured alcohol and dry with a compressed air.

ASSEMBLY





1. Install the piston seal.





Lubricate the piston seal with the rubber grease and install it in the caliper.





2. Lubricate the piston with brake fluid and partially install the piston.





3. Lubricate the dust piston with the rubber grease then install it on the piston.





4. Press the piston into the caliper until it bottoms in the bore.
5. Install the bleeder screw.
6. Install the bushing and new pin boots.
7. Lubricate the inside surface of the bushings with the rubber grease contained in the overhaul kit.