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Front Disc Brake Caliper Removal Overhaul And Installation

Updated on May 3, 2013

Given dust created by the braking system may contain asbestos, it should never be blown out with compress air neither should it be inhaled given it is harmful to one’s health. When doing any brake repair job always wear an approved filtering mask. Petroleum based solvents should never be use to clean brakes parts.

The caliper should be overhauled if there are visible sign of brake fluid leakage. Before starting the job it is essential that the required rebuild kit is available and always repair both of the calipers.

To begin this job the wheel nuts should be loosen and the vehicle raised and place securely on jack stands. The two bolts securing the caliper to the hub should now be removed then disconnect the brake hose from the caliper.

Proceed by plugging the hose to keep contaminants out of the braking system and to prevent losing any more brake fluid than is necessary. To begin the overhaul of the caliper, remove the boot set ring and the boot. Compress air can be used to push the piston out of the caliper housing. If compress air is not available, tap the caliper on a block of wood.

While doing this do not place any fingers between the piston and housing because if the piston comes out with force it can damage your finger. The piston bore wall and piston should be inspected for score marks, rust, pitting or bright areas. If there is any visible sign of damage, the complete caliper should be replaced.

If the caliper bore and piston is in good condition, remove the seal with a piece of wood or plastic tool to prevent any damage to the bore. All boots on the caliper should be removed and clean with brake part cleaner.

With all parts cleaned and armed with the correct rebuild kit soak the new seal and piston in clean brake fluid and install then into the piston bore. The piston should be square when it is being put into the bore and it should never be forced in but firm pressure should be applied to it by hand.

The new dust boot and set ring should now be installed and the sliding bushings which must be lubricated with silicone based grease can now be inserted into the caliper ears. Installation is the reverse of removal. The brake hose copper washers should be replace with new ones supplied in the kit before the brake hose is reconnected. Finish the job by bleeding all air from the braking circuit and check for any leaks at the hose connections. The brakes should now be tested to ensure it is functioning properly.


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