Brake Caliper Rear, Overhaul

Brake caliper rear, overhaul

Special tools:
115 8147 TORQUE SOCKET 1/2" 19 MM 115 8147 Torque Socket 1/2" 19 mm
981 4071 STRAIGHTENING TOOL 981 4071 Straightening Tool
999 2809 PRESS TOOL 999 2809 Press Tool
999 2917 EXTRACTOR 999 2917 Extractor

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.
- If brake pads are removed, go to Dismantling brake caliper.

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 EXTRACTOR 999 2917 Extractor 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 PRESS TOOL 999 2809 Press Tool and rubber insert as a counterhold in place of the removed piston.

- Use weatherstrip tool 981 4071 STRAIGHTENING TOOL 981 4071 Straightening Tool 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.lb).

Installing brake caliper




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

Finishing
- Go to Rear brake pads, replacement Brake Pads Rear, Replacement.