Disassembly Procedure
It will be necessary to fabricate one or more blocks of wood to the following dimensions to be used during this procedure:
- Must fabricate 1 block: 19 mm (3/4 in) X 72 mm (3 in) X 72 mm (3 in)
- Optional to fabricate 1 block, rather than using an old brake pad: 19 mm (3/4 in) X 72 mm (3 in) X 133 mm (5.25 in)
- Optional to fabricate 1 block to cushion piston removal: 19 mm (3/4 in) X 72 mm (3 in) X 133 mm (5.25 in)
- Place the caliper in a vise using plastic vise caps or suitable material to protect the caliper mounting bosses from the vise jaws.
- Place a discarded brake pad or the fabricated 133 mm (5.25 in) long block of wood over 2 adjoining caliper piston bores and secure in place with a non-marring C-clamp.
- Place the fabricated 72 mm (3 in) long block of wood over one of the opposing caliper piston bores and secure it in place with a non-marring C-clamp.
- Use clean cloths or the other fabricated 133 mm (5.25 in) long block of wood to cushion the interior of caliper housing during removal of the caliper piston.
Carefully remove the brake caliper piston (1) by directing low pressure compressed air into the brake hose fitting inlet.
- Move the fabricated 72 mm (3 in) long block of wood over the emptied caliper piston bore and secure it in place with a non-marring C-clamp.
- Move the clean cloths or the other fabricated 133 mm (5.25 in) long block of wood to cushion the interior of caliper housing during the removal of the piston.
Carefully remove the brake caliper piston by directing low pressure compressed air into the brake hose fitting inlet.
Using care to not scratch or mar the painted surfaces or piston bore, remove the caliper piston dust boot seals (1) using a flat-bladed tool. DISCARD the dust boot seals.
Using wooden or plastic tool, remove the caliper piston seals (1) from the brake caliper bores. DISCARD the caliper piston seals.
- Repeat steps 1 through 10 for the opposite side of the caliper.
- Remove the caliper from the vise and clean the entire caliper with denatured alcohol, or equivalent.
- Dry the caliper piston bores with non-lubricated, filtered compressed air.
- Inspect the caliper piston bores and piston seal counter-bores for scratches, cracks, pitting, and/or corrosion.
- If the caliper piston bores are scratched, cracked, or pitted, or if corrosion cannot be cleaned with denatured alcohol, replace the caliper assembly.
Front Brake Caliper Bleeder Valve Cap (2) - Remove
- Front Brake Caliper Bleeder Valve (1) - Remove
Protect the caliper painted surfaces while using the C-Clamp.
Do NOT clean the caliper piston bores by honing or cleaning with abrasives.