Front

Front Disc Brake Caliper/Description:

DISASSEMBLY
1. Remove disc brake caliper.

CAUTION: Use a wooden block and layers of shop towels to cushion possible impact of the caliper piston against the disc brake caliper iron when caliper piston comes out of the piston bore. Do not use a screwdriver or similar tool to pry caliper piston out of the bore, as damage to the caliper piston may result. If the caliper piston is seized and cannot be forced from the disc brake caliper, tap lightly around the piston while applying air pressure. Use extreme caution because the caliper piston can develop considerable force from pressure build-up.





2. Apply air pressure to the fluid port of disc brake caliper to remove caliper piston using rubber-tipped air gun.
3. Remove the dust boot from the disc brake caliper assembly.
4. Remove the rubber piston seal from the cylinder and discard it.
5. Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compressed air. Make sure that disc brake caliper bore and component parts are thoroughly clean.
6. Check cylinder bore and caliper piston for damage or excessive wear. Replace the caliper piston if it is pitted, scored, corroded or the plating is worn off.
7. Visually check disc brake caliper. If caliper housing is leaking, it should be replaced. If caliper piston is seized in the bore, a new disc brake caliper is required.
8. Inspect locating pin boots in disc brake caliper anchor plate to make sure they are sealed in groove. Replace damaged boots. Locating pin boots that are not properly sealed may cause disc brake caliper locating pins to corrode and brakes to drag.

ASSEMBLY
1. Install a new seal into caliper bore.
2. Install a new dust boot onto piston.
3. Clean foreign material from piston and bore and lubricate with brake fluid.
4. Start caliper piston into caliper bore by hand to assure correct alignment.

Retracting Caliper:

5. Place a wood block or another flat stock, like an old brake shoe and lining assembly, between a C-clamp and caliper piston. Do not apply clamp directly to caliper piston surface. This can result in damage to caliper piston. Be sure piston is not cocked.
6. Slowly press piston into caliper bore.
7. Make sure dust boot is tight in boot groove on caliper piston and in disc brake caliper.
8. Install disc brake caliper assembly as described.
9. Bleed brake system and road test.