Rear
Rear Brake Caliper Internal Components:
NOTE: Tools used in this procedure are part of Caliper Spring Compressor Set T87P-2588-B. Refer to Tools and Equipment for special tools.
DISASSEMBLY
1. Remove rear disc brake caliper assembly from vehicle.
2. Mount disc brake caliper in a vise. Use vise jaw protectors.
3. Using caliper piston adjuster turn disc brake piston and adjuster counterclockwise and remove disc brake piston and adjuster from caliper piston bore.
4. Remove and discard piston dust boot seal and piston seal from caliper bore.
WARNING: THE SNAP RING AND SPRING COVER ARE UNDER SPRING LOAD AND CARE SHOULD BE TAKEN WHEN REMOVING THE SNAP RING TO PREVENT INJURY.
Screw And Cross block:
5. Release tension from parking brake lever pin retainer clip and spring cover using screw and crossblock, a 6 mm washer head nut and a 14 mm standard 1/2-inch drive socket.
6. Remove snap ring retaining push rod assembly from disc brake caliper with suitable snap ring pliers.
7. Remove spring cover, spring, washer, key plate and pull out push rod and strut pin from caliper bore.
8. Remove and discard O-ring seal from push rod.
9. Remove parking brake return spring, unscrew limiting bolt and pull parking brake cable out of disc brake caliper.
CLEANING AND INSPECTION
^ Clean all metal parts with isopropyl alcohol.
^ Use clean, dry compressed air to clean out and dry grooves and passages.
^ Make sure caliper bore and component parts are completely free of any foreign material.
^ Inspect caliper bores for damage or excessive wear.
^ If rear disc brake piston and adjuster is pitted or scored or if plating is worn off, replace rear disc brake piston and adjuster assembly.
ASSEMBLY
1. Lightly grease parking brake lever bore and lever shaft seal with silicone brake caliper grease and dielectric compound. Press parking brake lever shaft seal into caliper bore.
2. Grease parking brake shaft recess and lightly grease parking brake lever. Insert parking brake lever into bore in caliper housing.
3. Screw limiting bolt into caliper housing. Tighten to 6-9 Nm (54-79 inch lbs.). Attach parking brake return spring to limiting bolt and insert free end into parking brake lever slot.
4. Install new O-ring seal in groove of push rod. Grease recess at push rod end with silicone brake caliper grease and dielectric compound.
5. Position strut pin into disc brake caliper and in recess of parking brake lever. Insert push rod into push rod bore of disc brake caliper. Make sure pin is positioned correctly between shaft recess and recess at end of push rod. Place key plate over push rod so locating nib fits into drilled locating hole in disc brake caliper. Install flat washer, push rod spring and spring retainer in sequence.
Rear Disc Brake Caliper Parking Brake Mechanism:
6. Insert outer spacer into piston bore.
Outer Spacer:
7. Insert inner spacer into piston bore.
Inner Spacer:
8. Place parking brake lever pin retainer clip inside of inner spacer.
CAUTION: Parking brake lever pin retainer clip should click into place. Do not over-compress spring.
9. Position spring compressor and screw and cross-block on push rod and lightly screw tool clockwise to compress spring. Install snap ring (circlip).
10. Install new piston seal in groove in disc brake caliper after lubricating seal with high performance DOT-3 motor vehicle brake fluid.
NOTE: Make sure one slot in piston face is positioned so it will engage with nib on brake shoe and lining.
11. Coat disc brake piston and adjuster and piston dust boot with clean high performance DOT-3 motor vehicle brake fluid. Install dust boot into piston bore of disc brake caliper. Spread dust boot over disc brake piston and adjuster and seat dust boot in piston groove. Rotate disc brake piston and adjuster clockwise using rear caliper piston adjuster until piston is fully seated.
12. Install and bleed disc brake caliper assembly as described.