Overhaul
CALIPER DISASSEMBLY
1. Mount rear disc brake caliper in a vise. Use vise-jaw protectors.
2. Using Rear Caliper Piston Adjuster T87P-2588-A, turn rear disc brake piston and adjuster counterclockwise and remove rear disc brake piston and adjuster from caliper piston bore.
Brake Caliper, Rear (Part 1 Of 2):
Brake Caliper, Rear (Part 2 Of 2):
3. Remove and discard piston dust boot seal and piston seal from caliper bore.
CAUTION: The parking brake lever pin retainer clip (circlip) and spring cover are under spring load. Care should be taken when removing the parking brake lever pin retainer clip (circlip) to prevent injury.
4. Release tension from parking brake lever pin retainer clip and spring cover using screw and crossblock (part of T87P-2588-B tool kit), a 6 mm washer head nut and a 14 mm standard (1/2 -inch) drive socket.
5. With suitable snap-ring pliers, remove parking brake lever pin retainer clip (circlip) that retains push rod assembly, from rear disc brake caliper.
6. Remove spring cover, RH anti-rattle spring cover, washer, key plate and pull out push rod and strut pin from caliper bore.
7. Remove and discard rear brake caliper piston seal from push rod.
8. Remove parking brake return spring. Unscrew limiting bolt (2A795) and pull parking brake lever out of caliper housing.
CLEANING & INSPECTION
- Clean all metal parts with isopropyl alcohol.
- Use clean, dry compressed air to clean out and dry grooves and passages.
- Make sure caliper bore and component parts are completely free of any foreign material.
- Inspect caliper bores for damage or excessive wear. If rear disc brake piston or adjuster is pitted, scored or plating is worn off, replace damaged parts.
CALIPER ASSEMBLY
1. Lightly grease parking brake lever bore and lever shaft seal with Silicone Brake Caliper Grease and Dielectric Compound. Press parking brake lever shaft seal into caliper bore.
2. Grease parking brake shaft recess and slightly grease parking brake lever shaft. Insert shaft into bore in caliper housing.
3. Screw limiting bolt into caliper housing. Tighten to 6-9 Nm (54-79 inch lbs.). Attach parking brake return spring to limiting bolt and insert free end into parking brake lever slot.
4. Install a new rear brake caliper piston seal in groove of push rod. Grease recess at push rod end with Silicone Brake Caliper Grease.
Brake Caliper, Rear. Internal Park Brake Components:
5. Position pin into Caliper housing and in recess of parking brake lever shaft. Install seal on push rod. Insert push rod into push rod bore of caliper housing. Make sure pin is positioned correctly in shaft recess and recess at end of push rod. Place locating washer over push rod so locating nib fits into drilled locating hole in caliper housing. Install flat washer, right hand anti-rattle spring and spring retainer in sequence.
NOTE: Tools used in Steps 6 through 8 are part of Rear Caliper Spring Compressor Set T87P-2588-B.
Inner Spacer:
6. Insert inner spacer into piston bore.
7. Place parking brake lever pin retainer clip inside of inner spacer.
CAUTION: Parking brake lever pin retainer clip should click into place. To prevent damage, do not overcompress right hand anti-rattle spring.
8. Position spring compressor and screw and crossblock on push rod, and lightly screw tool clockwise to compress right hand anti-rattle spring. Install parking brake lever pin retainer clip (circlip).
9. Install new piston seal in groove in caliper housing after lubricating seal with High Performance DOT-3 Motor Vehicle Brake Fluid.
NOTE: Make sure one slot in rear disc brake piston and adjuster face is positioned so it will engage with nib on brake shoe.
10. Coat rear disc brake piston and adjuster and piston dust boot with High Performance DOT-3 Motor Vehicle Brake Fluid. Install dust boot into piston bore of rear disc brake caliper. Spread dust boot over rear disc brake piston and adjuster and seat dust boot in piston groove.
11. Rotate rear disc brake piston and adjuster clockwise using Rear Caliper Piston Adjuster T87P-2588-A until piston is fully seated.
11. Install and bleed caliper.