Front

- Raise and support vehicle, then remove wheel.
- Remove brake pads.
- Loosen brake line nut and pull guide pin dust cover off carrier.
- Support weight of caliper body and slide body and pin out of carrier.
- Remove upper guide pin bolt and remove caliper body.
- Disconnect and plug caliper hose.

DISASSEMBLY

Removing Caliper Piston:

- Eject the piston by gently applying low pressure air to the inlet port. Use a piece of wood to prevent the piston from being damaged.
- The piston dust cover cannot be removed until the piston has been ejected.





- Remove the piston, pull out the dust cover and extract the piston seal from the bore.
- Remove the bleed screw and clip from the caliper body.

CLEANING AND INSPECTION

CAUTION: NEVER USE GASOLINE. When cleaning brake components only use the recommended fluid. Use of gasoline, paraffin or other mineral based fluids can prove dangerous.

- Examine all the components for signs of wear, damage and corrosion. Pay particular attention to the piston and cylinder bore.
- Remove body corrosion with a wire brush or wire wool. No attempt should be made to clean a badly corroded or scored cylinder bore.

GUIDE PINS
- Inspect the guide pins, be sure that they are not corroded or seized, but are free to move in the pad carrier bracket.
- If the pins are difficult to remove or are corroded in anyway, they MUST be replaced together with new dust covers.
- Whenever the guide pins are removed, new guide pin bolts must be fitted.

CAUTION: NO ATTEMPT SHOULD BE MADE TO CLEAN CORRODED PINS.

- Inspect all parts and renew as necessary.

REASSEMBLING

CAUTION: Be sure that working surfaces and hands are clean. Use only brake fluid of the correct specification to lubricate the new seals when fitting.

- Lubricate the new piston seal, carefully fit to the inner groove of the piston bore.
- Lubricate, and fit the dust cover over the piston. Continue pulling the dust cover along the piston, extending the convolutions, until the inner sealing lip is almost at the end of the piston.
- Fit the piston and dust cover assembly into the piston bore. Locate the dust cover lip in the groove of the piston bore.
- Gently but firmly push the piston fully home through the dust cover.

NOTE: Be sure that the dust cover is not trapped between the piston and the bore, and that the inner lip of the dust cover is correctly located in the inner groove in the piston bore.

- Refit the bleed screw to the caliper body.
- Lubricate the guide pins and bores with the special grease, Molykote 111, supplied in the Service Kit or available as Girling Part No. 74947191.


CAUTION: DO NOT USE ANY OTHER TYPE OF GREASE.

Guide Pin:

- Fit the guide pin dust covers to the guide pins. Push each guide pin into its bore in the carrier. Be sure that each dust cover fits over the lip on the carrier.


NOTE: When fitting the guide pins, pucker the dust covers to expel any trapped air.

- Refit the caliper to the feed hose and tighten; release the hose clamp.
- Align the caliper to the carrier, be sure that the upper guide pin dust cover fits over the lip on the caliper body.
- Fit and tighten a new upper guide pin bolt. Pivot the caliper to allow the brake pads to be fitted.

NOTE: If the integral pad spring is damaged, or the pads are worn to the minimum thickness, then new pads MUST be fitted.

- Position the brake pads in the carrier. The pad with the wear indicator plug is fitted next to the piston.

Harness Routing:

- Be sure that the harness is correctly routed.
- Rotate the caliper to its normal position on the carrier. Be sure that the integral pad springs are located correctly against the caliper body and are not twisted or jammed in the viewing aperture.
- Press the caliper body against spring effort to line up the lower guide pin and fit a new guide pin fixing bolt. Be sure that the guide pin dust covers are correctly fitted over the lips on the caliper body and the pad carrier.
- Tighten the top and bottom guide pin fixing bolts to the correct torque.
- Fit the pad wear indicator plug into the clip and reconnect. Be sure that the harness cannot foul or chafe.
- Refit the road wheel.
- Repeat the procedure for the other brake calipers, as required.