Disassembly/Assembly

DISASSEMBLY

Fig. 4 Removing Piston From Caliper:

1. Disconnect hose from the caliper being careful not to lose copper washers.
2. Remove caliper as outlined above.
3. Drain brake fluid from caliper.
4. Pad caliper interior with clean shop towels and apply compressed air to remove piston, Fig. 4. Use just enough air pressure to ease piston out of bore. When applying compressed air do not place fingers in front of piston in an attempt to catch or protect it as this could result in serious injury.
5. Carefully pry dust boot out of bore.
6. Using a small piece of wood or plastic, remove piston seal from bore. Do not use a metal tool of any kind to remove seal as it may damage bore.
7. Remove bleeder valve.

ASSEMBLY

Fig. 5 Installing Boot To Piston:

Fig. 6 Installing Boot To Caliper:

1. Lubricate caliper piston bore and new piston seal with clean brake fluid. Position seal in bore groove.
2. Lubricate piston with clean brake fluid and assemble a new boot into the groove in the piston so the fold faces the open end of the piston, Fig. 5.
3. Using care not to unseat the seal, insert piston into bore and force the piston to the bottom of the bore.
4. Position dust boot in caliper counterbore and install, Fig. 6. Check the boot installation to be sure the retaining ring molded into the boot is not bent and that the boot is installed below the caliper face and evenly all around. If the boot is not fully installed, dirt and moisture may enter the bore and cause corrosion.
5. If available, use new copper washers discarding the old washers and install the brake hose to the caliper.
6. Install pads and caliper assembly.