Disc Brake Caliper Overhaul: Reassembly

1. Apply light coat of brake paste to piston and seal. Fit seal in groove, install piston in bore and press into bore with piston installer clamp (US 1023/5). Lightly coat inside of dust boot with brake paste, and fit to piston.
2. Using press clamp (VW 442), press dust cap onto bore groove and seat piston. Install dust boot retainer (if equipped). Install damping plates. Repeat procedure for other piston.

1. Reverse disassembly procedure. Coat piston with brake paste. Use a vise to seat piston.
2. Use a brass drift to fit brake cylinder to floating frame. Make sure both grooves in mounting frame are pushed over ribs on floating frame. Make sure piston is properly positioned. See Figure .

Fig 1: Girling Disc Brake Assembly (Except Vanagon & Quantum)

To reassemble, reverse disassembly procedure. Coat pistons and seals with brake paste before refitting.

1. Install piston seal in bore. Slide dust seal on piston. Lubricate piston and cylinder bore with brake paste.
2. Install piston and insert inner lip of dust seal into groove of caliper bore. Press piston in as far as it will go with tool (US 1023/4). When completely inserted, outer lip of dust seal must slip into groove in piston.

Fig 1: Girling Disc Brake Assembly (Quantum) Note new-type caliper for Quantum.

1. Coat seals, dust boot, cylinder bore and piston with brake paste. Coat guide pins with silicone grease.
2. Reverse disassembly procedure. Seat dust boot with brass drift. Long guide pin is installed in top hole of caliper housing.