Rebuild

Fig. 6 Exploded View:

DISASSEMBLY
1. Drain brake fluid from caliper.

Fig. 5 Removing caliper piston:

2. Position caliper with shop cloths, Fig. 5, and apply compressed air to fluid inlet port to ease piston from bore. Do not attempt to catch piston or to protect it when applying compressed air, since personal injury is possible.
3. Remove boot from piston, then the piston seal from bore, Fig. 6. Use wooden or plastic tool to remove piston seal since metal tools may damage piston.
4. Remove bleeder screw.

ASSEMBLY

NOTICE: Clean all parts in denatured alcohol or brake parts cleaner before assembly and dry them with dry compressed air

1. Coat square cut piston seal with clean brake fluid, then install seal into piston bore. Work seal into groove with clean fingers.
2. Install and torque bleeder screw to 100 inch lbs.

Fig. 7 Installing Caliper Piston Boot:

3. Lubricate boot and tool J-24548 with clean brake fluid, then place dust seal on tool, allowing 1/4 inch of tool to extend past small lip of boot, Fig. 7.
4. Place dust seal and tool over piston bore, then work large lip of boot into seal groove, Fig. 8. Ensure dust seal is fully seated.

Fig. 8 Installing piston in caliper:

5. Lubricate caliper piston and insert through tool. Center piston in bore and use a hammer handle to apply pressure to install piston halfway into bore, Fig. 8.
6. Remove tool J-24548 and seat small lip of boot in caliper piston groove, then bottom piston in bore.