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Disc Brake Caliper - Rear (Mark VII): Reassembly

  1. Apply a coat of clean brake fluid to new caliper piston seal and install in cylinder bore. Ensure seal is not twisted and is seated fully in the groove. Install new dust boot by seating the flange squarely in outer groove of caliper bore.
  2. Coat piston adjuster assembly with clean brake fluid, and install in cylinder bore. Spread dust boot over piston and seat in piston groove. Mount caliper in a vise. Fill piston adjuster assembly with clean brake fluid to bottom edge of thrust screw bore.
  3. Coat a new thrust screw "O" ring seal with clean brake fluid and install in groove in thrust screw. Using 1/4" Allen wrench, install thrust screw by turning into piston adjuster assembly until top surface of thrust screw is flush with bottom of threads bore. Use care to avoid cutting "O" ring seal.
  4. Index thrust screw, so that notches on thrust screw and caliper housing are aligned. Install anti-rotation pin.
    NOTE: Thrust screw and operating shaft are not interchangeable from side-to-side because of ramp direction in ball packets. Pocket surface of operating shaft and thrust screw are stamped with proper letter (R or L), indicating part usage.
  5. Place a ball in each of three pockets of thrust screw, and apply a liberal amount of Silicone Dielectric Grease (D7AZ-19A331-A), on all components in parking brake mechanism.
  6. Install operating shaft on balls. Install thrust bearing on operating shaft. Install new lip seal and "O" ring on end retainer. Coat "O" ring seal and lip seal with a light film of silicone grease. Install end retainer in caliper.
  7. Hold operating shaft firmly seated against internal mechanism while installing end retainer to prevent mislocation of balls. If lip seal is pushed out of position, reseat seal. Tighten end retainer to 75-95 ft. lbs. (101-103 N.m).
  8. Install parking brake lever on keyed spline so lever arm points down and rearward, allowing parking brake cable to pass freely under axle. Tighten lever retaining screw to 16-22 ft. lbs. (22-29 N.m). Ensure parking brake lever rotates freely after tightening.
  9. Arrange caliper in a vise and bottom piston with Piston Turning Tool (T75P-2588-B). Install new pin insulator in caliper housing. Ensure both insulator flanges straddle housing holes. Install caliper on vehicle.
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