Non-Turbocharged Models

Disassembly
1. Position a block of wood in front of the piston, then force out the piston blowing compressed air into flexible hose attachment. Do not place fingers in front of piston when using compressed air.

Fig. 3 Exploded view of disc brake caliper.:

2. Remove piston boot, Fig. 3, then use a screwdriver to remove piston seal.
3. Remove bleeder and cap from caliper.




Inspection
1. Check rotor, caliper body and support bracket for distortion or cracking and replace, if necessary.
2. Inspect cylinder bores and piston for wear, scuffing or corrosion and replace, if necessary.
3. Inspect slide pin, piston seal and piston boot for wear, bending, distortion, cracks corrosion or other conditions and replace, if necessary.



Assembly
1. Install bleeder and cap. Torque bleeder to 5.8 ft. lbs.
2. Apply rubber grease to cylinder wall and piston seal, then insert piston seal into cylinder bore.
3. Apply rubber grease to the sliding portion of the piston and install piston boot.
4. To install piston and piston boot, proceed as follows:
a. Insert edge of dust boot into boot groove.
b. Slowly force piston into cylinder.
c. Push piston fully into cylinder.