FS III

FS III front brake calipers, assembly overview

Note:
^ When carrying out repairs install all parts supplied in repair kit. New brake calipers are filled with brake fluid and are pre-bled.
^ Apply a thin coating of assembly lubricant G 052 150 A2 to brake cylinders, pistons and seals.

FS III front brake calipers, assembly overview:

1 - Dust cap
2 - Bleeder valve
^ Apply a very thin coating of assembly lubricant G 052 150 A2 to threads before installing

3 - Cap
^ insert into mounting bushing

4 - Guide pins, 28 Nm
5 - Mounting bushing
^ Insert into brake caliper housing

6 - Brake caliper housing

7 - Protective seal
^ Do not damage when inserting piston

8 - Piston
^ Apply a very thin coating of assembly lubricant G 052 150 A2 to piston before inserting

9 - Seal

Front brake caliper piston, removing and installing

Special tools, testers and auxiliary items required





^ Trim removal wedge 3409





^ Piston resetting tool T10145

Removing





- Force piston out of brake caliper housing using compressed air.

Note:
^ Place a piece of wood in the recess to prevent damage to the piston.





- Remove seal using trim removal wedge 3409.

Note:
^ When removing make sure that the surface of the cylinder is not damaged.

Installing
- The surface of the piston and seal must only be cleaned with methylated spirit and then dried.
- Apply a very thin coating of assembly lubricant G 052 150 A2 to piston and seal before fitting.
- Insert seal into brake caliper housing.





- Place protective seal with outer sealing lip on the piston





- Using trim removal wedge 3409, insert inner sealing lip into groove in cylinder.

Note:
^ When doing this hold piston in front of caliper housing.





- Press piston into brake caliper housing using piston retaining tool T10145.

Note:
^ The protective seal outer sealing lip will then locate in the piston groove.