Rebuild

Rear Caliper:

DISASSEMBLY
1. Remove caliper assembly. Removal
2. Mount caliper in a vise. Use vise jaw protectors.

Removing/Installing Piston:

3. Using Rear Caliper Piston Adjuster T87P-2588-A or equivalent, turn piston counterclockwise and remove piston from caliper piston bore.
4. Remove and discard piston dust boot seal and piston seal from caliper bore.
5. With suitable snap-ring pliers, remove snap ring retaining push rod assembly from caliper.

WARNING: The snap ring and spring cover are under spring load. Care should be taken when removing the snap ring.

6. From caliper bore, remove spring cover, spring, washer, key plate and pull out push rod and strut pin.
7. Remove and discard O-ring seal from push rod.
8. Remove parking brake lever return spring. Unscrew parking brake lever stop bolt and pull parking brake lever out of caliper housing.

CLEANING AND INSPECTION
1. Clean all metal parts with isopropyl alcohol or brake parts cleaner. Use clean, dry compressed air to clean out and dry grooves and passages. Ensure caliper bore and component parts are completely free of any foreign material.
2. Inspect caliper bores for damage or excessive wear. If piston is pitted, scored or plating is worn off, replace piston assembly.

ASSEMBLY
1. Lightly grease parking brake lever bore and lever shaft seal with silicone dielectric grease. Press parking brake lever shaft seal into caliper bore.

Parking Brake Lever Assembly:

2. Grease parking brake shaft recess and slightly grease parking brake lever shaft. Insert shaft into bore in caliper housing.
3. Screw return spring stop bolt into caliper housing. Tighten to 6-9 Nm (4.5-7 ft lb). Attach parking brake lever return spring to stop bolt and insert free end into parking brake lever slot.
4. Install a new O-ring seal in groove of push rod. Grease recess at push rod end with silicone dielectric grease.

Push Rod Assembly:

5. Position strut pin into caliper housing and in recess of parking brake lever shaft. Insert push rod into push rod bore of caliper housing. Ensure pin is positioned correctly between shaft recess and recess at end of push rod. Place key plate over push rod so that locating nib fits into drilled locating hole in caliper housing. Install flat washer, push rod, spring and spring cover in order.

Outer Spacer:

6. Insert outer spacer into piston bore.

Inner Spacer:

7. Insert inner spacer into piston bore.



8. Place snap ring inside of inner spacer.



9. Position spring compressor and screw and crossblock on push rod, and lightly screw tool clockwise to compress spring. Install snap ring.

CAUTION: Snap ring should click into place. Do not overcompress spring.

10. Install new piston seal in groove in caliper housing after lubricating seal with DOT 3 brake fluid.
11. Coat piston and piston dust boot with DOT 3 brake fluid. Install dust boot into piston bore of caliper. Spread dust boot over piston and seat dust boot in piston groove. Rotate piston clockwise using Rear Caliper Piston Adjuster T87P-2588-A or equivalent until piston is fully seated.

NOTICE: Ensure one slot in piston face is positioned so it will engage with nib on brake pad.

12. Install caliper assembly.