Rear Caliper Overhaul: Reassembly

Coat sliding bushing, dust boot, caliper boot, piston seal and piston with lithium soap base glycol grease. Install piston seal into caliper bore. Install piston into caliper bore. Install dust boot and sliding bushing. Make sure seal does not fold under. Make sure bushing flange faces inward into boot.

Coat main pin boot, sliding pin and boot, piston seal, piston and dust boot with lithium soap base glycol. Install piston seal and piston into caliper. Install cylinder boot and boot set ring in caliper. Using 21 mm socket, press main pin boot in. Install dust boot and sliding bushing. Bushing flange must face toward inside of caliper.

1. Put lithium soap base glycol grease on main pin, sliding bushing, strut pin, adjusting bolt, piston and all soft parts. On MR2 model, install stopper pin. Pin should be .098" (25 mm) from caliper to underside of head. Install cable support bracket.
2. On all models, install lever boot. Install lever, ensuring boot aligns with groove in lever seal. On MR2 models, ensure lever clears overlap on caliper. On all models, install spring and ensure that lever touches stopper pin. On Corolla RWD model, make sure that clearance between cable support bracket and upper side of lever is .0197-.0275" (.5-.7 mm). Use cable support bracket mount bolt to adjust clearance.
3. On all models, install strut. Ensure needle rollers do not catch on caliper hole. Install new "O" ring on adjusting bolt. Reassemble adjuster bolt with stopper, plate, spring and spring retainer. Use threaded compressor to tighten component parts of adjusting bolt assembly. Ensure that inscribed surface of stopper faces UP and notches of spring case line up with notches on stopper.
4. Install adjusting bolt assembly. Install snap ring with opening toward bleeder side. Remove threaded compressor. Pull up strongly on adjusting bolt as it should not move. Move parking brake lever by hand. Ensure adjusting bolt moves smoothly. Install piston seal in bore of cylinder.
5. Using piston spanner, slowly turn piston clockwise into caliper until it will go no further. Center of piston stopper groove must align with positioning protrusion on caliper. Place boot and set ring into caliper. On MR2 model, press main pin boot in using 21 mm socket. On all models, install dust boot and sliding bushing. Ensure seal does not fold under. Boot must be installed with flange facing inward.