Rebuild

Brake Caliper:

DISASSEMBLY
1. Remove the caliper assembly.
2. Remove brake pads.

NOTICE: Inner pad removal force may be as high as 45-90 Nm (10-20 ft lb).

3. Apply air pressure to the fluid port in the caliper with a rubber-tipped nozzle to remove the piston.

CAUTION: Do not use a screwdriver or any similar tool to pry piston out of bore. It will result in damage to piston. Cushion piston's impact against caliper when blowing it out of bore by placing shop towels or rags between piston and caliper bridge.

4. Remove the dust boot from the caliper assembly.
5. Remove the rubber piston seal from the cylinder and discard it.

CLEANING AND INSPECTION
^ Clean all metal parts with isopropyl alcohol or brake parts cleaner. Then, clean out and dry the grooves and passageways with compressed air. Make sure caliper bore and component parts are thoroughly clean.

Piston Inspection:

^ Check the cylinder bore and piston for surface irregularities or small chips and cracks. Replace piston if damaged.

ASSEMBLY
1. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove.
2. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore.
3. Coat the piston with brake fluid, and install the piston in the cylinder bore. When installing piston back into bore, use a wood block or another flat stock, like an old pad lining assembly, between C-clamp and piston.

CAUTION: Do not apply C-clamp directly to piston surface. This can result in damage to piston. Be sure piston is not cocked.

4. Ensure dust boot is tight in boot groove on piston and in caliper.
5. To install inner pad with 3-finger clip attached to pad into piston, grab each end of pad, making it square with piston. Push firmly until pad clip snaps into piston. Do not allow pad or clip tangs to cock during installation.
6. Install caliper.