Rear Brake Caliper, Repair [PPP]

PPP. Rear brake caliper, repair

PPPA. Brake caliper rear, overhaul

Special tools: 115 8147, 981 4071,999 2809,999 2917

[PPPA1]

Preparations

- Remove wheel

[PPPA2]

Removing brake caliper






- Clean brake caliper carefully.
- Remove protective cap from bleed nipple and open nipple.
- Lock pedal in depressed position using a pedal jack.
- Collect emerging brake fluid.
- If brake pads are removed, go to [PPPA5].

[PPPA3]

Removing brake pads






- Knock out split pins with a 3 mm (0.12") mandrel.
- Remove retaining spring.

[PPPA4]






- Remove brake pads and shims. Use puller 999 2917 if brake pads will not come out easily.

[PPPA5]

Dismantling brake caliper






- Remove brake pipe from brake caliper.
- Remove brake caliper mounting bolts (1) and let caliper down.
- Drain remaining brake fluid.

[PPPA6]

Dismantling brake caliper






Warning! Take care not to get fingers caught when piston is pushed out.

- Remove dirt guard (3).
- Put a block of wood in front of pistons (4) and press out carefully with compressed air.
- Remove pistons. If one piston comes out but the other will not, use clamp 999 2809 and rubber insert as a counterhold in place of the removed piston.

[PPPA7]

- Use weatherstrip tool 981 4071 or similar to remove O-rings (5).
- Remove bleed nipple (7).

Note! Do not separate the two halves. This requires special pressure testing equipment and special assembly fluid.

[PPPA8]

Cleaning and inspection

- Clean components with turpentine. Check for wear, damage, cracks and rust. Replace components it necessary.
- Always replace 0-rings and dirt guard during overhaul. Take particular care to clean ducts and grooves for O-rings and dirt guard.
- If cylinders are badly marked, scratched etc, replace caliper complete.
- Remove minor rust deposits with fine sandpaper.

[PPPA9]

Assembling brake caliper






- Coat pistons, cylinder lining and 0-rings with brake fluid.
- Install 0-rings (5) in cylinder grooves.
- Install pistons (4) in brake caliper, one first and then the other.
- Install new dirt guard (3).
- Check that it fits in its groove in pistons and brake caliper.
- Install bleed nipple (7), tighten to 5 Nm (4 ft lb).

[PPPA1O]

Installing brake caliper






- Install brake caliper. Use new bolts and tighten to 60 Nm (45 ft lb).
- Install brake pipe on caliper, tighten to 14 Nm (10 ft lb).

[PPPA11]

Finishing

Refer to: Rear Wheel Brake Linings, Replacement [NNN] Brake Pads, Rear, Replacing