Rear Disc Brake Caliper: Reassembly

NOTE: Ensure all parts are clean before reassembly. Use only new replacement parts. Use only DOT3 or 4 clean brake fluid. Do not allow dirt or other foreign matter to contaminate brake fluid. Do not mix different brands of brake fluid. Avoid spilling brake fluid on painted, plastic or rubber surfaces as it can damage the finish. Wash spilled brake fluid off immediately with clean water.

CAUTION: Avoid damaging cam boot, since it must be installed before cam.

Pack all cavities of the needle bearing with a commercially available assembly lube. See Fig 5 . Coat new cam boot with a commercially available assembly lube and install into caliper. Install cam with threaded end facing up. Do not allow cam boot lips to turn outside in.
Install the lever, lock washer and parking nut, then tighten parking nut. Install return spring.
Install pin in cam. Install a new O-ring on sleeve piston. Install sleeve piston so hole in bottom of piston is aligned with pin in cam, and two pins on piston are aligned with holes in caliper. See Fig 6 .

NOTE: Install bearing A with open end facing the spacer.

Install a new cup with its groove facing bearing A side on adjusting bolt. Fit bearing A, spacer, adjusting spring B and spring cover on adjusting bolt, and install into caliper cylinder.
Adjust Brake Spring Compressor (07HAE-SG00100) as shown. See Fig 3 . Install brake spring compressor between caliper body and spring guide. Compress spring until it bottoms out. Ensure flared end of spring cover is below circlip groove. Install circlip. Ensure circlip is fully seated in groove. Remove brake spring compressor.
Install adjusting nut, adjusting spring A, and washer, then secure with circlip.
Coat new piston seal and piston boot with silicone grease and install them in caliper, using caution as not to damage piston boot. Coat outside of piston with silicone grease, and install on adjusting bolt while rotating clockwise.
Install brake pad retainers and brake pads. Install pad spring on caliper. Install caliper on caliper bracket and tighten caliper mounting bolts. Connect brake hose to caliper with new sealing washers and tighten banjo bolt. Connect parking brake cable to arm on caliper. Fill brake reservoir up and bleed the brake system. See BLEEDING BRAKE SYSTEM under BLEEDING.