Disassembly and Reassembly

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
CALIPER
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

CAUTION: Piston sliding surface is plated. Do not polish with emery paper 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, rust and other damage. Replace if any of the above conditions are observed.

ROTOR
Runout

1. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications 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 the specification, turn rotor with on car brake lathe.
Rotor repair limit: 26.0 mm (1.024 inch)

For brake rotor removal information see Wheel hub or wheel hub (locking), service and repair in Steering and Suspension / Suspension. Suspension

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 property.
- Lubricate with new brake fluid before installing plastic pistons into cylinder body.