Disassembly and Assembly

Disassembly

CAUTION: Do not use a screwdriver or any similar tool to pry caliper piston out of bore. It will result in damage to caliper piston. Cushion caliper piston's impact against disc brake caliper when blowing it out of bore by placing a wooden block or shop towels between caliper piston and caliper bridge. Use care because the caliper piston can develop considerable force from pressure buildup.


1. Remove disc brake caliper from front disc brake caliper anchor plate.





2. Disconnect the disc brake caliper from the hydraulic system, then apply air pressure to the fluid port in the disc brake caliper with Rubber-Tipped Air Gun 100-D009 (D93L-7000-A) or equivalent to remove caliper piston. If piston is seized and cannot be forced from the disc brake caliper, the disc brake caliper must be replaced.


Assembly
1. Clean foreign material from caliper piston surfaces and lubricate with brake fluid before inserting into disc brake caliper. Always install new seal and dust boot.





2. Start caliper piston into disc brake caliper housing by hand for correct alignment.

Retracting Caliper:

3. When installing caliper piston back into bore, use wood block or other flat stock, like an old brake shoe lining assembly, between C-clamp and caliper piston. Do not apply C-clamp directly to caliper piston surface. This can result in damage to caliper piston. Be sure caliper piston is not cocked.
4. Ensure dust boot is tight in boot groove on caliper piston and in disc brake caliper.
5. Install disc brake caliper.