Front Disc Brakes

^ Tool Required:
- J 36349 Front Dust Boot Seal Installer

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) may come out with force, resulting in serious injury.

NOTICE: Do not use a metal tool to remove the piston seal from the caliper housing bore. Using a metal tool may damage the caliper bore or seal groove.

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

DISASSEMBLE
1. Caliper. Refer to "CALIPER."








2. Piston, using compressed air into the caliper inlet hole. Piston will come out through piston boot.

Inspect
- Piston for scoring, nicks, corrosion, worn or damaged chrome plating. Replace piston if any of these conditions are found.

3. Caliper boot, be careful not to scratch housing bore.
4. Piston seal from groove in caliper bore, with a small wooden or plastic tool.

Inspect
- Caliper bore and seal grooves for scoring, nicks, corrosion, and wear.
^ Use crocus cloth to polish out light corrosion.
^ Replace caliper housing if corrosion in and around seal groove will not clean up with crocus cloth.
- Bolt boots for cuts, tears, or deterioration. If damaged, replace.
- Caliper bolts for corrosion or damage. Replace if corroded. Do not attempt to polish away corrosion.
- Seal groove in caliper bore for nicks or burrs. If found replace caliper.

5. Bleeder valve cap and bleeder valve from caliper housing.

Clean
- All parts in clean, denatured alcohol.
- Dry with filtered, unlubricated compressed air.
- Blow out all passages in caliper housing and bleeder valve.





ASSEMBLE
1. Bleeder valve and bleeder valve cap to caliper housing.
- Tighten bleeder valve to 13 Nm (115 inch lbs.).
2. New lubricated piston seal into caliper bore grooves.
- Make sure piston seal is not twisted.
3. Lubricated boot onto piston.





4. Piston and boot into bore of caliper and push to bottom of bore.
- Lubricate piston OD with clean brake fluid before installing.





5. Seat caliper boot in caliper housing counterbore using J 36349.
6. Caliper. Refer to "CALIPER."