Rear Calipers

Brake caliper rear, overhaul
Special tools: 115 8147, 981 4071, 999 2809, 999 2917
Preparations
^ Remove wheel.

Removing brake caliper
^ Clean brake caliper carefully.
^ Remove protective cap from bleed nipple and open nipple.





^ Lock pedal in depressed position using a pedal jack.
^ Collect emerging brake fluid.

Removing brake pads





^ Knock out split pins with a 3 mm (0.12") mandrel.
^ Remove retaining spring.





^ Remove brake pads and shims. Use puller 999 2917 if brake pads will not come out easily.

Dismantling brake caliper








^ Remove brake pipe from brake caliper.
^ Remove brake caliper mounting bolts (1) and let caliper down.
^ Drain remaining brake fluid.

Dismantling brake caliper

Warning: Take care not to get fingers caught when piston is pushed out.





^ Remove dirt guard (3).
^ Put a block of wood in front of pistons (4) and press out carefully with compressed air.
^ Remove pistons. If one piston comes out but the other will not, use clamp 999 2809 and rubber insert as a counterhold in place of the removed piston.
^ Use weatherstrip tool 9814071 or similar to remove O- rings (5)
^ Remove bleed nipple (7).

Note: Do not separate the two halves. This requires special pressure-testing equipment and special assembly fluid.

Cleaning and inspection
^ Clean components with T-spirit. Check for wear, damage, cracks and rust. Replace components if necessary.
^ Always replace O-rings and dirt guard during overhaul. Take particular care to clean ducts and grooves for O-rings and dirt guard.
^ If cylinders are badly marked, scratched etc. replace caliper complete.
^ Remove minor rust deposits with fine sandpaper.

Assembling brake caliper





^ Coat pistons, cylinder lining and O-rings with brake fluid.
^ Install O-rings (5) in cylinder grooves.
^ Install pistons (4) in brake caliper, one first and then the other.
^ Install new dirt guard (3).
^ Check that it fits in its groove in pistons and brake caliper.
^ Install bleed nipple (7), tighten to 5 Nm (4 ft. lbs.).

Installing brake caliper





^ Install brake caliper. Use new bolts and tighten to 60 Nm (45 ft. lbs.).
^ Install brake pipe on caliper, tighten to 14 Nm (10 ft. lbs.).

Finishing
^ Go to Rear brake pads, replacement.