Overhaul

CAUTION: Do not place fingers in front of the piston in an attempt to catch or protect the piston when applying compressed air to the caliper brake nose connector hole. Serious injury could result. Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the block of wood in place, damage may occur.

1. Caliper from vehicle. Refer to Brake Caliper, Replacement. Replacement

Caliper Piston Removal:

2. Insert a block of hard wood or shop cloth into the caliper interior to catch the piston as it is forced out of the bore with compressed air.
3. Piston from caliper by applying compressed air to the caliper brake hose connector hole.

Removing Piston Seal:

4. Piston seal from caliper using a thin, bladed tool.
5. Bleeder valve and cap from caliper.
6. Caliper mounting bolts, with boots, from caliper.

Clean
- Caliper slide bushings, caliper set ring, piston, caliper carrier, and caliper housing in clean brake fluid.
- Dry with unlubricated, compressed air.
- Blow out all passages in the caliper housing and bleeder valve.

Inspect
1. Piston for scoring, corrosion, and any damage to the chrome plating. Replace piston if any of these conditions are observed.
2. Caliper bore for scoring, pitting, and corrosion. Use crocus cloth to polish out any light corrosion. If corrosion cannot be removed, replace the caliper.

Install or Connect
1. New caliper mounting bolts and boots into caliper.
2. Lubricate piston seal and boot with clean brake fluid.
3. Bleeder valve and cap to caliper.
^ Tighten Bleeder valve to 10 Nm (89 inch lbs.).

4. New piston seal into groove on caliper housing. Make sure the seal is not twisted.
5. New boot to piston.

Seating Boot On Caliper:

6. Fit boot into caliper groove and cylinder with fingers.
7. Insert piston into cylinder by hand and fit boot inside piston groove.
8. To confirm that boot is fitted, pull piston out of cylinder a little but do not remove it.
9. Insert piston into cylinder by hand.
10. Caliper to vehicle. Refer to Brake Caliper, Replacement. Replacement