REAR DISC BRAKE CALIPER Disassembly 1. Remove brake caliper. See REAR DISC BRAKE CALIPER under REMOVAL & INSTALLATION . Remove pad spring from caliper. Using Wrench (07916-6390001), rotate piston counterclockwise to remove. See Fig. 7 . Ensure caliper bore or piston components are not damaged. Replace if necessary.
2. Install Brake Spring Compressor (07HAE-SG00100) between caliper body and spring cover. Position lock nuts as shown, then rotate shaft until plate just contacts caliper body. See Fig. 8 . Rotate shaft clockwise 1/4 - 1/2 turn to compress spring. DO NOT turn shaft more than 1/2 turn, as inner components may be damaged. 3. Lower lock nuts to plate, then tighten securely. Remove retaining ring. Relax spring compressor before removing it. Remove adjuster bolt. Remove spring cover, adjuster spring, spacer, bearing and cup. Remove sleeve piston and "O" ring. Remove pin from cam. Remove return spring, parking nut, spring washer, lever, cam, and cam boot. 4. Remove cam boot. Clean all parts in clean brake fluid. Inspect components for excessive wear or damage. Replace as required. Replace all rubber components. Reassembly 1. Pack needle bearing with Brake Cylinder Grease (08733-B020E). Pack new cam boot with brake cylinder grease and install into cylinder body. Lubricate pin contact area of cam with brake cylinder grease. Install cam and lever assembly in caliper body. 2. Install return spring. Install lever and spring washer. Apply Loctite to parking nut and install. Tighten nut to 21 ft. lbs. (28 N.m). Install rod into cam. Install new "O" ring onto sleeve piston. Align hole in bottom of sleeve piston with rod in cam. 3. Align pins on piston with holes in caliper. See Fig. 9 . Apply grease to new cup and install with groove facing bearing side of adjuster bolt. Assemble bearing, spacer, adjuster spring, and spring cover onto adjuster bolt. Install adjuster bolt assembly into caliper bore. See Fig. 10 . Ensure open end of bearing faces spacer.
4. Install Brake Spring Compressor (07HAE-SG00100) into caliper body. Rotate shaft until lock nut contacts plate. Ensure flared end of spring cover is below snap ring groove in caliper bore. See Fig. 11 . Install snap ring into groove of caliper bore. Remove spring compressor. Ensure snap ring is properly seated in groove. 5. Coat new piston seal and piston boot with silicone grease, and install in caliper bore. Apply grease to piston outside diameter, and install onto push rod while turning piston clockwise. Ensure piston boot is not damaged during installation. To complete reassembly, reverse disassembly procedure. Install caliper. Bleed system. See BLEEDING PROCEDURES under BLEEDING BRAKE SYSTEM.
In my opinion, it's MUCH easier to buy a remanufactured caliper, and bolt it on. When the rubber seals come apart like this, if you don't know how this is done, and even experienced mechanics don't normally rebuild calipers, I have done a few, and if the piston, or seal is damaged AT ALL during assembly, the caliper will leak! Also the best policy is to replace calipers in PAIRS, they are the same age and general condition, replace both and save the headache!
Saturday, August 28th, 2010 AT 4:19 PM