Contents: Disassembly ↧ Assembly ↧
Disassembly
Note: Brake caliper repair shown using a 2500 series front caliper as an example.
1. Remove the brake caliper.
2. Drain the brake fluid from the caliper.
Caution: When pushing the piston out with compressed air, do not catch the piston with your hand, this will cause injury.
Note: The brake caliper pistons are made of phenolic plastic. The pistons have stainless steel inserts that come into contact with the brake pads.
3. Secure the caliper in a vice.
4. Place a wooden block between the pistons and the outer bridge of the caliper.
5. Cover the support with a towel.
6. Apply compressed air to the brake hose mounting hole and push out the pistons.
7. If one of the pistons cannot be removed in this way, perform the following operations.
- a) Install the pressed out piston back into place.
- b) Using a clamp and a small wooden block, insert the piston into the caliper to half the length of the piston.
- c) Place the second plate in front of the other piston.
- d) Cover the support with a towel.
- d) Apply compressed air to the brake hose mounting hole and push out the piston.
8. Remove the pistons (3) from the caliper holes.
9. Remove the dust boots (4) from the caliper. Do not scratch the dust boot seat in the caliper.
10. Using a plastic or wooden rod, remove the piston seals (2) from the caliper. _
11. Remove the cover (5) of the drain screw (6).
12. Remove the drain screw.
13. Wash all metal parts with denatured alcohol. Dry the parts with compressed air. Blow out the caliper channels.
14. Replace pistons or caliper if:
- there are scratches or scoring on the caliper and/or piston;
- there is corrosion or pitting in the caliper bores;
- there is damage to the piston.
Assembly
Caution: When assembling the brake caliper, lubricate the parts to be installed with clean brake fluid immediately before installation. This will prevent accidental contamination.
1. Lubricate the piston, piston seal, and piston hole in the caliper with brake fluid (dOT-3 fluid).
2. Install the rectangular piston seal into the bore groove in the caliper.
3. If the seal is twisted, straighten it out.
4. Install the dust cover on the piston so that the fold of the cover is directed towards the caliper body.
5. Install the piston into the caliper (without distortion) and insert the dust boot into the groove in the caliper hole.
6. Place a wooden block on the piston.
7. Using uniform pressure from your hand, push the piston into the caliper.
8. Remove the plate.
9. Screw the drain screw into the caliper housing. Tightening torque 72 Nm.
10. Install the drain screw cap.
11. Install the caliper on the car.