FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Disassembly and Reassembly









Disassembly

WARNING: Do not place your fingers in front of piston.

CAUTION:
- Do not scratch or score cylinder wall.
- CL28VD type front disc brake uses plastic pistons. Handle them carefully.





1. Push out pistons and dust covers with compressed air. Use a wooden block so that both pistons come out evenly.
2. Remove piston seals with a suitable tool.

Inspection-Caliper
CYLINDER BODY
- Check inside surface of cylinders for scores, rust, wear, damage or 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 the surface with a fine emery sandpaper. Replace cylinder body if necessary.

CAUTION: Use brake fluid to clean. Never use mineral oil.

PISTON





CAUTION: Piston sliding surface is plated. Do not polish with emery sandpaper even if rust or foreign objects are stuck to sliding surface. Check pistons for uneven surface, chips or cracks. Replace if any of these conditions are observed.

SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of these conditions are observed.

Inspection-Rotor
RUNOUT





1. Check runout using a dial indicator.
- Make sure that wheel bearing axial end play is within specification before measuring.
Maximum runout: 0.07 mm (0.0028 inch)
2. If the runout is out of specification, machine rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).

THICKNESS





Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 inch)
If thickness variation exceeds specification, machine rotor with on car brake lathe.
Rotor repair limit: 24.0 mm (0.945 inch)

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.

CAUTION:
- Secure dust seal properly.
- Lubricate with new brake fluid before installing plastic pistons into cylinder body.