Caliper-Front Disc Brake: Disassembly

NOTE: Before disassembling the brake caliper, remove it from the vehicle. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - REMOVAL)

NOTE: Before disassembling the brake caliper, clean and inspect it. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - CLEANING) (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSPECTION)

WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice.

CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion.

Mount the caliper in a vise equipped with protective jaws.

Fig 1: Piston Removal Using Air Pressure
Courtesy of DAIMLERCHRYSLER CORP.

1 - WOOD BLOCK

WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure.
Place a wooden block (1) in the caliper as shown in illustration.
If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out.
Remove the piston from the caliper.
Remove the dust boot from the piston and discard it.

Fig 2: Piston Seal Removal
Courtesy of DAIMLERCHRYSLER CORP.

1 - TRIM STICK

2 - SEAL

CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges.
Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal.
Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth.