Contents: Disassembly ⤓ Assembly ⤓
Note: Some models use dual-cylinder disc brake calipers. The refurbishment of these calipers is similar to that described below for single-cylinder assemblies, with the only difference being that in this case, twice as many seals and dust boots must be replaced.
Disassembly
1. Remove the caliper from the brake assembly (see Section Removal and installation of disc brake calipers) and transfer it to a clean workbench.
2. Depending on the design of the brake mechanism, the piston is removed from its cylinder in one of two ways. In the first case, you should insert a wooden block into the assembly, which will act as a support, then feed compressed air into the inlet of the caliper, which will push the piston out of the cylinder.
Attention! Be careful - make sure that when pushing out the piston, your fingers do not end up between its end surface and the thrust surface! In the second case, the piston is removed from the cylinder by turning it out.
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3. Carefully inspect the removed piston for scratches, scoring, traces of corrosion and signs of damage to the chrome plating; replace it if necessary.
4. If equipped, remove the anti-squeal insert.
5. Using a blunt screwdriver, remove the dust cover and extract the sealing cuffs from their grooves in the cylinder - try not to damage the cylinder mirror.
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6. Remove the protective cap of the bleed valve, then unscrew the latter from the caliper body.
7. Carefully inspect the piston working surface and cylinder bore for scratches, cracks and signs of excessive wear. Assess the condition of the threaded fasteners.
8. Traces of light corrosion can be removed by polishing the working surfaces of the elements with fine-grained sandpaper.
9. Finally, wipe the surfaces with methyl alcohol and dry with compressed air.
Assembly
1. After lubricating, screw the bleed valve back into place and install the protective cap on it.
2. Insert new sealing cuffs into the cylinder grooves, making sure that the cuffs are not twisted in the grooves.
3. Lubricate the cylinder mirror.
4. Insert the piston (assembled with the dust cover installed on it) into the cylinder and push it in until it stops.
5. The boot is fitted into the caliper body using a special mandrel.
6. Install the caliper in its regular place (see Section Removal and installation of disc brake calipers).
7. Install the wheel and lower the car to the ground.
8. Bleed the brake system (see Section Bleeding the brake system).