Disassembly and Assembly

Fig. 3 Front disc brake assembly. W/dual piston calipers:

Refer to Fig. 3 when performing a caliper overhaul operations.

DISASSEMBLY
1. Remove calipers as previously described under REMOVAL/INSTALLATION.
2. On ES 250 models, remove two sliding bushings and four dust boots.
3. On all models, remove cylinder boot set rings and cylinder boots.
4. Place a piece of cloth between piston and caliper, then using compressed air remove pistons from cylinder.
5. Remove piston seals.
6. On Except ES 250 models, remove sliding pins from torque plate. Using a chisel and hammer, tap out dust boots.

ASSEMBLY

Fig. 9 Exploded View Of Brake Caliper. W/dual Pistons:

1. Apply lithium base soap base glycol grease to parts indicated with arrows, Fig. 9.
2. On ES 300 & LS 400 models with single piston calipers, install dust boots and sliding pins, insert sliding pin with sliding bushing into bottom side of caliper.

Fig. 10 Dual Piston Caliper Bushing Styles:

3. On models with dual piston calipers, install dust boots, then insert sliding pin with bushing style A into upper part of caliper and sliding pin with bushing style B into lower part of caliper, refer to Fig. 10.
4. On all models, install piston seals and pistons in cylinders.
5. Install cylinder boots and set rings in cylinders.
6. On ES 250 models, install dust boots and sliding bushings.
7. On all models, install caliper and bleed brakes as previously described.