Rear Brake Caliper

Removal

PROCEDURE

1. Raise the rear of the vehicle and support it on stands.

2. Remove the wheel.

3. Release the parking brake cable sheath and disconnect the cable from the lever on the caliper.

4. To minimize fluid loss, tightly close the reservoir cap with polyethylene film placed under it, or pinch off the hoses.

5. Clean the banjo fitting of the hose and remove the bolt, then plug the openings.

6. Remove the two gaskets.

7. Remove the brake pads.

8. Remove the upper caliper guide pin bolt.

9. Remove the caliper from the bracket.

10. If necessary, remove the caliper bracket from the spindle.

Disassembly

PROCEDURE

1. Carefully clean the caliper.

2. Pull out the guide pins by the bolt heads, which are screwed into the pins.

3. Remove the rubber guide pin boots.

4. Turn the piston counterclockwise and remove it from the cylinder.

5. Remove the boot.

6. Compress the cylinder spring by pressing on the cap, and remove the retaining ring from the cylinder groove.

7. Gradually release the spring, then remove the spring ring, cap, spring, retaining plate, pushrod and spacer.

8. Using a wooden stick, remove the cylinder seal.

9. Disconnect the spring from the parking brake lever, remove the nut, and remove the lever from the caliper.

10. Wash all parts in clean brake fluid or alcohol.

11. Replace all seals and boots without exception.

12. Inspect the caliper condition, paying particular attention to the piston and the inner surface of the cylinder. Replace worn parts. The caliper or caliper bracket is not available separately.

13. Minor cylinder bore defects can be removed by polishing with fine emery cloth. A piston with the same defects must be replaced. Do not polish the piston.

14. Check the threads on the caliper guide pins. There must be no play in the guide pins in the caliper.

15. Blow out the brake fluid passages.

16. Before assembly, check that all parts are clean.

17. Install a new boot on the parking brake lever cam.

18. Install the spring and washer, then tighten the nut.

19. Lubricate the cam with brake fluid and install it in the caliper.

20. Make sure that when the lever is turned, the slot in the cam aligns with the hole in the push rod.

21. Install the lever spring.

22. Dip the new cylinder seal in fluid and install it in the cylinder groove.

23. Install a new O-ring on the push rod, and apply rubber grease to the spacer and push rod.

24. Install all parts into the caliper.

25. Install the lock plate so that its slot fits the flat part of the push rod and its protrusion engages the recess in the caliper.

26. Install the snap ring.

27. Install the spring and cap, compress the spring, and install the snap ring.

28. Apply rubber grease to the cylinder boot lip and install it on the piston.

29. Lubricate the piston and the caliper cylinder walls with brake fluid. Screw the piston into the cylinder by turning it clockwise.

30. Install the second lip of the boot on the caliper.

31. Install new boots on the caliper guide pins.

32. Replace the rubber bushing in the upper guide pin.

33. Before installing in the caliper, lubricate the guide pins with brake fluid.

Installation

PROCEDURE

1. Install the caliper bracket on the steering knuckle and tighten the bolts.

2. Install the caliper, apply thread locking compound to the upper guide pin bolt threads, and tighten the bolt to the specified torque.

3. Install the brake pads.

4. Check that the caliper moves freely in the bracket.

5. Connect the hose, installing two new gaskets and tightening the banjo bolt.

6. Connect the parking brake cable to the lever and install the bracket. On some vehicles, insert the cable housing into the clip, and align the projection on the bracket with the recess in the caliper body.

7. Remove the polyethylene film from the reservoir cap (or remove the clamps from the hoses).

8. Bleed air from the wheel brake hydraulic circuit (if the other circuits were not disturbed).

9. Press the brake pedal several times.

10. Install the wheels and lower the vehicle.

11. Before driving, check the brake operation.