REMOVAL & OVERHAUL
See Figures 1 through 6
- With the vehicle securely raised and its wheels removed, disconnect the front caliper brake hose at its support bracket and the rear unit line from the inside caliper.
- Tape the open end of each line to prevent dirt from entering.
- Pull the cotter pins, retaining pins, and brake pads, and unbolt the caliper from its mounting bracket.
- Remove the two large bolts and split the caliper case.
- Remove the fluid transfer hole O-rings.
- The pistons are retained by ring-like boots. To remove them, fully depress the pistons and, with a prytool, lever the boots from their seats. Remove the pistons, springs, and seals, using air pressure if necessary.
- Clean all parts with non-mineral based solvent and compressed air, and replace the rubber parts with those in the brake service kit.
- Inspect the piston bores for damage or corrosion. Polish corroded bores with crocus cloth and, if this is not enough, replace the caliper. Replace all self-locking bolts.
- Maintain the proper caliper piston-to-bore clearance as indicated in the chart.
- Reverse the disassembly procedure to reassemble. Lubricate parts with brake fluid.
Remember, when positioning the piston seal on the piston, that it goes in the groove nearest the piston flat end with the lap facing the largest end. If placement is correct, the seal lips will be in the groove and not extend over the groove step. Bleed the brake system after installation.