Brake Caliper: Service and Repair

FRONT DISC BRAKE





COMPONENTS

REMOVAL
CALIPER ASSEMBLY
1. Remove the wheel and tire.





2. Disconnect the brake hose.

CAUTION:
- Do not brake fluid on the vehicle; it may damage the paint If brake fluid does contact the paint, wash it off immediately with water.
- To prevent spills, plug the hose inlets with rags or shop towels.

3. Remove the cylinder mounting bolt.





4. Remove cylinder and pads from the caliper bracket.
5. Remove the caliper mounting bolts from the knuckle.
6. Remove the caliper mounting bracket.

DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.

NOTE:
1. Do not put your fingers in front of the piston when using compressed air.





2. Be careful not to splatter the brake fluid.





3. Remove the piston seal from the caliper by using a screwdriver.

CAUTION: Do not damage the piston wall surface.

INSPECTION
1. Check the caliper for wear, damage, cracks and dust.
2. Check the piston for dust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and dust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, dust, wear and cracks.

CAUTION:
1. Do not use sand paper on the piston surface.
2. All rubber parts must be replaced with new parts.





6. Inspect the disc by using a caliper and a dial gauge.
Thickness of disc mm (inch)
Standard value: 19mm (0.75 inch)
Service limit: 17mm (0.67 inch)
Runout of the disc mm (inch): 0.04 (0.002)
Difference of thickness mm (inch): 0.01 (0.0004)

NOTE:
1. Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the outer edge of the disc and at 45° intervals.
If you subtract the minimum of measurements from the maximum, you get the difference of the disc thickness.
2. When measuring the disc runout, fix a dial gauge approximately 5mm from the outer edge of the disc, and rotate the disc 360°.
At this time, if you subtract the minimum of measurements from the maximum, you get the disc runout.

7. If necessary, replace the brake disc.

REASSEMBLY
1. Clean all components except the pads and shims with isopropyl alcohol.





2. Apply rubber grease on the piston seal and install the piston seal in the cylinder.
3. Assemble the piston and piston boots according to the following procedure
1. Apply rubber grease to the caliper bore, the outside surface of the piston and the piston boot.
2. Install the piston boot on the piston as illustrated.





3. Insert the piston boot in the inner groove of the caliper and push the piston into the caliper.
4. Assemble the sliding parts according to the following procedure.
1. Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot and sleeve boot





2. Insert the boot into the groove of the caliper.





5. Install the pads.

NOTE: Be careful so that the disc or pad is not contaminated by grease.





6. Tighten the brake hose connecting bolt.

Tightening torque Nm (kg-cm, ft. lbs.)
Sliding pin 34 - 44 Nm (350-450 kg-cm, 26-33 ft. lbs.)
Sliding bolt 22 - 31 Nm (220-320 kg-cm, 16-23 ft. lbs.)
Carrier mounting bolt 64 - 74 Nm 650-750 kg-cm, 48-54 ft. lbs.)
Brake hose mounting oil bolt 25 - 29 Nm (250-300 kg-cm, 18-22 ft. lbs.)

NOTE:
1. Check that the surface of the pin and bolts are not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting parts.

INSTALLATION
CALIPER ASSEMBLY
Installation is the reverse of removal.
1. Be careful not to spill grease or oil on the pad and brake disc contact surface.
2. Tighten the caliper mounting bolt to the specified torque.





3. Install the brake hose.
4. Bleed the system.