Rear Brake Caliper Overhaul Export

1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement .




Caution: 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) can fly out with force and could result in serious bodily injury.

Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

2. Blow compressed air into the brake caliper hose hole in order to remove the brake caliper piston. The piston will come out through the piston boot.
3. Inspect and replace the brake caliper piston if any of the following conditions are found:

•

Scoring

•

Nicks

•

Corrosion

•	Worn or damaged chrome plating




4. Use a flat-bladed tool in order to remove the brake caliper piston boot (2). Do not scratch the housing bore.




Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result.

5. Use a small wooden or plastic tool in order to remove the piston seal (4) from the groove in the caliper bore.
6. Inspect the caliper bore and the seal grooves for the following conditions:

•

Scoring

•

Nicks

•

Corrosion

•

Wear

7. Use a piece of crocus cloth in order to polish out light corrosion.
8. Replace the caliper housing (3) if corrosion in and around the seal groove cannot be cleaned with a piece of crocus cloth.
9. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged.



10. Inspect and replace any brake caliper bolt pin boots (3) that exhibit any of the following conditions:

•

Cuts

•

Tears

•	Deterioration

11. Inspect the brake caliper bolts for corrosion or damage. Replace any corroded brake caliper bolts. Do not attempt to polish away the corrosion.



12. Remove the bleeder valve cap (17) and the bleeder valve (16) from the brake caliper housing (15).
13. Clean all the parts with clean, denatured alcohol.
14. Dry all the parts with filtered, non-lubricated compressed air.
15. Use filtered, non-lubricated compressed air in order to blow out all of the passages in the caliper housing and the bleeder valve.

Tools Required

J 36349 Dust Boot Seal Installer

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the bleeder valve and the bleeder valve cap to the caliper.

Tighten
Tighten the bleeder valve to 11 N·m (97 lb in).

2. Install a new lubricated piston seal (6) to the caliper bore groove. Ensure that the piston seal is not twisted.



3. Install the lubricated piston boot (1) onto the brake caliper piston (2).
4. Lubricate the brake caliper piston (2) with clean brake fluid.
5. Install the brake caliper piston with the brake caliper piston boot into the bore of the caliper. Push the brake caliper piston to the bottom of the bore.



6. Seat the caliper boot in the brake caliper (1) using the J 36349 Dust Boot Seal Installer.
7. Install the brake caliper. Refer to Rear Brake Caliper Replacement .