Overhaul
Removal1. Remove one road wheel nut and mark the stud to wheel relationship. Remove the remaining nuts, and remove the road wheel.
2. Remove the spring clips (1) securing the brake pad retaining pins (2); withdraw the retaining pins. Recover the anti-rattle springs (3) and withdraw the brake pads (4).
3. Loosen the caliper feed pipe union (1) at the support bracket and disconnect the feed pipe from the caliper. Plug the pipe to prevent the loss of fluid and ingress of dirt.
4. Break the lock wire (2) and remove the two bolts and spring washers (3) securing the brake caliper and the stub axle carrier.
NOTE: Make a careful record of the shim(s) fitted between the steering arm and the brake caliper.
5. Remove the caliper.
Overhaul
CAUTION: Do not under any circumstances remove, or attempt to remove, the bolts securing the halves of the caliper together.
1. Remove the spring clips (1) retaining the piston dust covers (2). Remove the dust covers. To expel the pistons, carefully feed compressed air into the caliper fluid inlet port; remove the pistons (3) from the caliper.
CAUTION: Take care not to damage the cylinder bores when extracting the seals.
2. Carefully pry each seal (4) from the recess in each piston cylinder bore. Remove the bleed screw. Using Castrol/Girling (or similar) Brake Cleaning Fluid, thoroughly clean all components.
3. Examine the pistons and cylinder bores for signs of abrasion, 'scuffing', scratches or corrosion. If any of the above conditions are present, then a new component (caliper assembly) must be fitted.
3. Coat the new seals with brake lubricant, or new, clean brake fluid.
4. Fit the new seals (4) into the recesses in the cylinder bores using ONLY finger pressure.
5. Lubricate the pistons (3) with brake lubricant, or new, clean brake fluid and install them into the cylinder bores.
6. Fit new dust covers (2) over the pistons and locate the dust cover lip in the outer groove of the piston. Push the pistons fully home and install the dust cover in the outer grooves of the cylinder bores.
7. Install the dust cover spring clips (1). Install and tighten the bleed screw.
INSTALLATION
1. Install the caliper to the stub axle carrier; ensure that the correct value of shim(s) are fitted between the brake caliper and the steering arm. Tighten the bolts to 68 to 81 Nm (50.3 to 59.9 ft lb).
2. Lock-wire the caliper bolt heads.
3. Reconnect the caliper feed pipe, tighten to 10 to 12 Nm (7.4 to 8.9 ft lb). Tighten the support bracket lock nuts.
Note: Examine the brake pads for wear and damage. If the lining thickness is less than 4 mm (0.16 in), install new brake pads.
4. Install the brake pads (4). Fit the retaining pins (2), anti-rattle springs (3) and the spring clips (1).
5. Align the wheel with the marked stud and install the wheel. Tighten the wheel nuts to 88 to 102 Nm (65.1 to 75.5 ft lb).
6. Bleed the brakes. Brake Bleeding