Spark

Front Brake Calliper Overhaul

Warning: Refer to Brake Dust Warning in the Preface section.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Warning: Do not place fingers in front of the calliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

Caution: Use clean cloths to pad interior of calliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

1. Remove the brake calliper from the vehicle. Refer to Front Brake Caliper Replacement .
2. Remove the brake calliper piston from the calliper bore by directing low pressure compressed air into the calliper bore through the fluid inlet hole.



3. Remove the piston dust boot seal (1) from the seal counter-bore in the calliper (4). Discard the boot seal.
4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal.



5. Remove the brake bleeder valve cap (2).
6. Remove the brake bleeder valve (1).

Note: Do not use abrasives to clean the brake calliper piston.

7. Inspect the calliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
8. Clean the brake calliper piston bore and seal counterbore, and the calliper piston with methylated spirit, or equivalent.
9. Dry the calliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.
10. If light rust or light corrosion are present in the calliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the calliper assembly.
11. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the calliper bore, replace the calliper assembly.
12. Inspect the calliper piston for cracks, scoring, and/or damage to the plating. Replace the calliper piston if any of these conditions exist.

1. Lubricate the new piston seal (3) with the brake fluid from a clean, sealed brake fluid container. Refer to Brake System Specifications for the recommended brake fluid.
2. Install the lubricated, new piston seal (3) into the calliper bore.
3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container onto the outer surface area of the calliper piston (2). Refer to Brake System Specifications for the recommended brake fluid
4. Install the bottom half of the calliper piston (2) into the calliper bore.



5. Install the new piston dust boot seal (1) over the calliper piston (2).
6. Compress the calliper piston (2) to the bottom of the calliper bore.
7. Fully seat the piston dust boot seal (1) into calliper counter-bore.

Caution: Refer to Fastener Caution in the Preface section.




8. Install the brake bleeder valve (1) to the calliper and tighten to 8.5 N·m (75 lb in).
9. Install the brake bleeder valve cap (1).
10. Install the brake calliper to the vehicle. Refer to Front Brake Caliper Replacement .