Rear (25/35 Series)

Brake Caliper Overhaul - Rear (25/35 Series)

Caution: Refer to Brake Dust Caution in Service Precautions.
Brake Dust Caution


Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.
Brake Fluid Irritant Caution


Disassembly Procedure







Important: Replace all the components included in the repair kits used to service this brake caliper.
Lubricate the rubber parts with clean brake fluid to make assembly easier.
The torque values specified are for dry. con lubricated fasteners.
Perform the service operations on a clean bench, free from all mineral oil materials.

1. Remove the brake caliper from the vehicle.

Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.







2. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing.
3. Remove the 2 pistons.
4. Remove the 2 piston boots.
5. Remove the 2 piston seals.
6. Remove the brake caliper bleed screw cap.
7. Remove the brake caliper bleed screw.
8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing.







9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed.
10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
11. Clean all the parts not included in the repair kit with denatured alcohol.
12. Dry all the parts with non lubricated filtered compressed air.
13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.




Assembly Procedure

Notice: Refer to Fastener Notice in Service Precautions.
Fastener Notice







1. Install the brake caliper bleed screw.
Tighten the brake caliper bleed screw to 12 Nm (106 lb in).

2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid.
4. Install new the seal into the brake caliper bore seal groove.
5. Ensure that the seal is not twisted.
6. Lubricate the brake caliper bore and the piston with brake fluid.
7. Install the boot and the piston
7.1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening.
7.2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore.
7.3. Push down the piston to the bottom of the brake caliper bore.
7.4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore.
7.5. Repeat steps 5 and 6 for the remaining piston.

8. Install the brake caliper to the vehicle.