Disassembly and Assembly

Fig. 2 Rear Disc Brake Caliper Assembly:

Fig. 13 Seating Caliper Piston:

Fig. 14 Positioning Caliper Piston To Brake Pad Nib:

Disassembly

1. Remove caliper assembly from vehicle.
2. Position caliper assembly in a soft jawed vise.
3. Using tool No. T75P-2588-B or equivalent, rotate caliper piston counterclockwise to remove from caliper bore, Fig. 13.
4. Remove piston dust boot and seal from caliper piston bore, Fig. 2.
5. Remove snap ring retaining pushrod to caliper. Use care when removing, as the snap ring and spring cover are under spring load.
6. Remove spring cover, spring, washer, key plate and pushrod and strut pin from caliper.
7. Remove O-ring from pushrod.
8. Remove parking brake lever return spring, then remove brake lever stop bolt and pull lever from caliper.

Cleaning & Inspection

1. Clean all metal components with isopropyl alcohol.
2. Use compressed air to clean out passages and grooves.
3. Inspect caliper bore for damage and excessive wear.
4. Inspect caliper piston for pitting, scoring or worn plating and replace as necessary.

Assembly

1. Apply a light coating of silicone dielectric compound to parking brake lever bore and parking brake lever seal, then position seal into caliper bore, Fig. 2.
2. Apply silicone dielectric compound to parking brake lever shaft, then insert shaft into caliper housing bore.
3. Install O-ring into groove on pushrod, then apply silicone dielectric compound to recesses in pushrod.
4. Place strut pin into caliper housing and into recess of parking brake lever shaft.
5. Position pushrod into caliper housing bore, ensuring strut pin is properly located between shaft recesses and recess at end of pushrod.
6. Position key plate over pushrod, so that washer nib is located in hole in caliper housing.
7. Install flat washer, spring and spring cage into caliper bore.
8. Install snap ring using tool No. T87P-2588-P or equivalent. Ensure snap ring is properly seated in recess.
9. Lubricate replacement piston seal with clean brake fluid, then install seal into caliper bore groove.
10. Lubricate piston and dust boot with clean brake fluid, then install dust boot into caliper bore.
11. Position piston into dust boot, seating dust boot in piston groove.
12. Using tool No. T75P-2588-B or equivalent, turn piston in clockwise direction until piston is fully seated in caliper bore, Fig. 13.
13. Position one of the two slots on the piston so that it will engage the nib on the rear of the disc pad when the caliper is installed, Fig. 14.
14. Install caliper assembly.