Overhaul
DISASSEMBLY
WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF PISTON.
CAUTION: Do not scratch or score cylinder wall.
1. Push out piston with dust seal with compressed air.
2. Remove piston seal with a suitable tool.
INSPECTION
Cylinder Body
- Check inside surface of cylinder for score, rust, wear, damage and presence of foreign objects. If any of the above conditions are observed, replace cylinder body.
- Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
CAUTION: Use brake fluid to clean. Never use mineral oil.
Piston
- Check piston for score, rust, wear, damage and presence of foreign objects. Replace if any of the above conditions are observed.
CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface.
Slide Pin, Pin Bolt and Pin Boot
- Check for wear, cracks, rust and other damage. Replace if any of the above conditions are observed.
Rotor
Runout
1. Secure rotor to wheel hub with at least two M12 x 1.25 nuts.
2. Check runout using a dial indicator.
Maximum runout: 0.1 mm (0.004 inch)
Axial end play: 0.0 mm (0.0 inch)
NOTE: Make sure that wheel bearing axial end play is within the specifications before measuring.
3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705", or equivalent).
Thickness
- If thickness variation exceeds the specification, turn rotor with on-car brake lathe.
ASSEMBLY
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston.
3. Properly secure piston boot.