Overhaul

WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) may come out with force, resulting in serious injury.

CAUTION:
- Do not use a metal tool to remove the piston seal from the caliper housing bore. Using a metal tool may damage the caliper bore
or seal groove.

- Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the piston out of the bore. If the piston is blown out, even with the padding provided, it may be damaged.

REMOVE OR DISCONNECT
1. Caliper.

Removing Piston:

2. Piston, using compressed air in the caliper inlet hole. Piston will come out through piston boot.

- Inspect
- Piston for scoring, nicks, corrosion, worn or damaged chrome plating. Replace piston if any of these conditions are found.

Removing Boot:

Seating Boot Into Housing:

3. Caliper boot, being careful not to scratch housing bore.
4. Piston seal from groove in caliper bore, with a small wooden or plastic flat-bladed tool.

- Inspect
- Caliper bore and seal grooves for scoring, nicks, corrosion, and wear.
- Use crocus cloth to polish out light corrosion.
- Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth.
- Bolt boots for cuts, tears, or deterioration. If damaged, replace.
- Caliper bolts for corrosion or damage. Replace if corroded. Do not attempt to polish away corrosion.
- Seal groove in caliper bore for nicks or burrs. If found replace caliper.

5. Bleeder valve cap and bleeder valve from caliper housing.

- Clean
- All parts in clean, denatured alcohol.
- Dry with filtered, unlubricated compressed air.
- Blow out all passages in caliper housing and bleeder valve.

INSTALL OR CONNECT
1. Bleeder valve and bleeder valve cap to caliper housing.
- Tighten bleeder valve to 13 Nm (115 inch lbs.).
2. New lubricated piston seal into caliper bore grooves. Make sure piston seal is not twisted.

Seal, Piston, And Caliper Boot Installation:

3. Lubricated boot onto piston.
4. Piston and boot into bore of caliper and push to bottom of bore.
- Lubricate piston outer diameter with clean brake fluid before installing.
5. Seat caliper boot in caliper housing counterbore using J 36349 front dust boot seal installer, or equivalent.
6. Caliper.