Brake Caliper Overhaul Front

Tools Required

J 35777 Caliper Piston Seal Installer

1. Remove the caliper from vehicle. Refer to Front Brake Caliper Replacement .

Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

2. Remove the piston by directing low pressure compressed air into the caliper inlet hole.




Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove.

3. Remove the piston boot from the caliper.
4. Remove the piston seal from the caliper.
5. Remove the bleeder valve and cap from the caliper.



6. Clean all of the parts. Use clean, denatured alcohol. Dry all of the parts with non-lubricated, low pressure compressed air. Blow out all of the passages in the caliper body and the bleeder valve.
7. Inspect all of the parts as follows.

•	Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the piston if any damage is found.

•	Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore.

•	Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper.

8. Install the new piston seal. Lubricate the seal with clean brake fluid before installing.



9. Install the new piston dust boot seal over the piston.
10. Using theJ 35777 fully seat the boot in the caliper.
11. Install the bleeder valve cap and bleeder valve into the caliper.
12. Install the caliper onto the vehicle. Refer to Front Brake Caliper Replacement .

Brake Caliper Overhaul Rear

1. Remove the rear caliper from vehicle. Refer to Rear Brake Caliper Replacement .
2. Remove piston and piston boot (3) by turning the piston (2) counterclockwise, using a spanner type wrench.

Important: Do not use a metal tool for removal of the boot ring or piston seal.




3. Remove the boot ring from the groove in the caliper bore with a small wooden or plastic tool.



4. Remove the piston seal with a small wooden or plastic tool.



5. Remove the piston boot from the piston.



6. Remove the bleeder valve from the caliper body.

Important: The lever return spring is the only component in the parking brake mechanism that can be removed or replaced. Do not disassemble the parking brake mechanism. Replace the caliper if the parking brake is damaged or inoperative.

7. Replace the lever return spring if damaged.



8. Remove the snap ring from the piston with snap ring pliers.

Important: Replace the caliper piston if any of the internal parts are damaged.




9. Remove and inspect the spacer, wave washer, spacer, ball bearings, and adjusting nut from the piston.



10. Clean all of the parts with denatured alcohol. Dry all of the parts with dry and filtered low pressure compressed air. Blow out all of the passages in the caliper body and the bleeder valve.

Important: The piston sliding surface is plated. Do not polish with emery paper.

11. Inspect the piston for scoring, rust , wear, damage, or presence of foreign objects. Replace the piston if any of these conditions have occurred.

Important: Use new brake fluid to clean the caliper cylinder, do not use mineral oil.

Minor damage from light rust or foreign objects may be eliminated by polishing the cylinder surface with a fine crocus cloth.
12. Inspect the inside surface of the cylinder for scoring, rust, wear, damage, or presence of foreign objects. Replace the caliper body if any of these conditions have occurred.



13. Install the adjusting nut, ball bearings, spacer, wave washer, and spacer in the piston.



14. Install the snap ring in the piston.
15. Install the bleeder valve in the caliper body.



16. Lubricate the new piston seal with clean brake fluid .
17. Install the piston seal in the caliper bore.



18. Install the new boot on the piston.



19. Screw the piston (2) into the caliper body (1) using a spanner type wrench.



20. Install the boot ring inside the caliper counterbore against the piston boot.
21. Install the caliper onto the vehicle. Refer to Rear Brake Caliper Replacement .