Overhaul

Rear Caliper Internal Components:

DISASSEMBLY
1. Remove the adjuster screw plug.

Caliper, Rear. Adjuster:

2. Turn the brake adjuster screw clockwise until it is loose enough to remove.

WARNING: USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE.

CAUTION: Do not use a screwdriver or any other similar tool to pry the piston out of the bore. Piston damage could result.

Caliper, Rear. Piston Removal:

3. Position a block of wood between the piston and the rear disc brake caliper. Place rags over caliper, piston and wood block.
4. Apply compressed air to brake fluid port and force piston from bore.
5. Remove the dust seal from the piston and the snap ring and discard the seal.
6. Remove the rear disc brake adjuster spindle (2A874), the O-ring, and the brake connecting link (2Z999). Discard the O-ring.

CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove which could result in a leak.

7. Use a plastic or wooden pick to remove the piston seal from the bore, and discard the seal.
8. Clean all parts with new DOT-3 brake fluid. If denatured alcohol is used to clean brake parts, all parts must be air-dried completely and the coated with brake fluid.
9. Inspect and replace damaged parts.

ASSEMBLY

NOTE: Be sure the seal is not twisted and is firmly seated in the caliper bore.

^ To install, reverse the removal procedure.