Disassembly and Assembly

Disassembly and Assembly of Brake Caliper Assembly

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NOTE: Do not remove torque member, brake pads, shims, shim covers and pad retainers, when disassembling or assembling cylinder body

DISASSEMBLY
1. Remove sliding pin bolts, and then remove brake pads, shims, shim covers, and pad retainer from torque member and cylinder.

CAUTION: Do not drop brake pads, shims, shim cover and pad retainer from torque member.

2. Remove sliding pin boot from torque member.





3. As shown in the figure, using a flat-bladed screwdriver, remove retaining ring from cylinder body





4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.

CAUTION: Do not get your fingers caught in piston.





5. Using a flat-bladed screwdriver, remove piston seals from cylinder body.

CAUTION: Be careful not to damage cylinder inner wall.

INSPECTION AFTER DISASSEMBLY
Cylinder Body

CAUTION:
^ Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
^ Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above conditions are observed, replace cylinder body.
^ Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the torque member.

Piston

CAUTION:
^ Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are stuck to sliding surface.
^ Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above condition are observed.

Sliding Pin Bolts and Sliding Pin Boots
Check sliding pin bolts and sliding pin boots, for wear, damage and cracks. If damage or deformation is present, replace the applicable part.

ASSEMBLY





1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body.

CAUTION: Do not reuse piston seal.





2. Apply rubber grease to piston boots. Cover the piston end with piston boot, and install cylinder side lip on piston boots properly into groove on cylinder body

CAUTION: Do not reuse piston boot.





3. Apply brake fluid to piston, and press piston into cylinder body by hand to assemble piston side lip on piston boot properly into groove on piston.

CAUTION: Press piston evenly and change the pressing point to prevent the inner wall of cylinder from being rubbed.





4. Fix piston boot with retaining ring.

CAUTION:
^ Make sure boot is firmly in cylinder body groove.
^ Do not reuse retaining ring.

5. Install sliding pin bolts and sliding pin boots to torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the backside of brake pad and to both sides of shim, and attach inner shim and shim cover to inner pad, and the outer shim and outer shim cover to outer pad.





7. Assembling shims and shim covers to pad.

CAUTION: When attaching pad retainer, install it firmly so that it does not float up higher than torque member, as shown in the figure.

8. Install brake pad retainer and pad to torque member.
9. Install cylinder body Tighten sliding pin bolts to the specified torque. Refer to BR-25, Components.
10. After installing caliper assembly, refill with new brake fluid and bleed air.