Front Brake Caliper, Repair [OOO]

OOO. Front brake caliper, repair

OOOA. Brake caliper front, overhaul

Special tools: 115 8147, 981 4071

[OOOA1]

Preparations

- Remove wheel.

[OOOA2]

Draining brake fluid






- Clean brake caliper carefully.
- Remove protective cap from bleed nipple and open nipple.
- Lock pedal in depressed position with a pedal jack.
- Collect emerging brake fluid.
- Undo brake hose (1/2 turn).

[OOOA3]

Removing brake caliper and brake pads






- Undo brake hose (1/2 turn).
- Remove retaining spring (3) carefully to avoid deforming it.
- Remove protective caps (1) from the two locating pins (2).
- Remove locating pins, using 7 mm (0.276") hexagonal socket.

[OOOA4]

- Remove brake caliper carefully from mounting to avoid damaging brake hose.
- Remove brake pads.

[OOOA5]

Removing brake hose

- Unscrew brake caliper from brake hose.
- Drain remaining brake fluid.

[OOOA6]

Dismantling brake caliper






Warning! Take care to avoid getting fingers caught when piston is pushed out.

- Put a block of wood in front of piston. Push piston out carefully using compressed air.

[OOOA7]






- Remove dirt guard (3).
- Remove 0-ring (4). Use weatherstrip tool 981 4071 or similar so as not to damage edges of groove.
- Remove rubber bushings (7) and bleed nipple (5).

[OOOA8]

Cleaning and inspection

- Clean components in turpentine. Check for wear, damage, cracks and rust. Replace components if necessary.
- Always replace 0-ring and dirt guard during overhaul. Take particular care to clean ducts and grooves of 0- ring and dirt guard.
- If cylinder is badly marked, scratched etc., replace complete caliper.
- Remove minor rust deposits with fine sandpaper.

[000A9]

Assembling brake caliper






- Blow ducts clean with compressed air.
- Coat cylinder lining, piston (2) and new 0-ring (4) with brake fluid.
- Install lubricated 0-ring (4) in groove in cylinder. Install dirt guard in end of piston (see illustration).

[OOOA10]






- Install dirt guard in groove inside cylinder and push piston in carefully.
- Check that dirt guard slots into its groove in the piston.
- Check that dirt guard is in position properly.
- Install bleed nipple (5), tighten to 9 Nm (7 ft lb).

[OOOA11]

Finishing






- Install rubber bushings in brake caliper.
- Screw brake caliper onto hose by hand.
- Hang brake caliper up on a steel wire on front spring to avoid damaging hose.
- Refer to: Front Wheel Brake Linings, Replacement [MMM] Service and Repair