Front Brake Caliper Overhaul (J56)

Front Brake Caliper Overhaul (J56)

Tools Required

CH-47954 Installer, Caliper Seal


Removal Procedure
Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .


Important: Cap or plug the brake hose so as not to allow the brake system to become contaminated and to prevent fluid leaks.


1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (J56) (Rear Brake Caliper Replacement (J56))Rear Brake Caliper Replacement (JL9-J55) (Rear Brake Caliper Replacement (JL9-J55)) .

Important: Use a vise or holding fixture that has soft jaws to prevent damage to the aluminum body of the caliper.


2. Install the caliper in a vise.




3. Using the appropriate tools, position the tools between the inner and outer brake pads so that when the compressed air is applied, the pistons will not move.

Important: The following service procedure should be repeated until all pistons have been removed from the caliper.


4. Using the C-Clamp from the CH-47954 , hold the brake pad opposite the piston to be removed from the caliper.
Caution: Refer to Safety Glasses and Compressed Air Caution (Safety Glasses and Compressed Air Warning) .
5. Apply filtered, non lubricated compress air to the piston.




6. Remove the piston (1) from caliper.
7. After the inboard and outboard pistons have been removed, move to the next piston and repeat the clamping procedure until all pistons have been removed.
8. Using a long medium-bladed screwdriver, remove the dust seal (2) from the caliper body. Use caution as not to damage the caliper.
9. Using a small flat-bladed pocket screwdriver or equivalent, remove the piston seal (3).





Important: Perform the following service procedure only if the brake pipe is damaged.


10. Remove the brake pipe between the inboard and outboard pistons.



Installation Procedure






Important: Finger tighten the brake pipe before torquing to proper specification.


1. Install the brake pipe between the inboard and outboard pistons.

Tighten to 40 N.m (30 lb ft).





2. Position the piston seal (3) in the bore.
3. Install the piston (1) in the bore.
4. Position the dust seal (2) in the piston bore.





Important: When the dust seal is seated, the dust seal maybe slightly above the surface of the caliper, this is normal. The inner surface of the caliper is slightly curved.


5. Using the CH-47954 , install the dust seal in the following manner:

1. Position the C-Clamp and cup on the caliper.
2. Align the tool on the dust seal for the proper installation of the dust seal.
3. Slowly apply pressure to the dust seal.
4. Check the alignment of the dust seal to the bore.
5. If the position of the tool and dust seal has changed, reposition the tool on seal.
6. Fully seat the dust seal in the piston bore.
7. Repeat this procedure for the rest of the pistons that need to be serviced.

6. Remove the brake caliper from the vise.

Important: In the following service procedure, use caution as not to damage the dust seal.


7. Using a small flat-bladed pocket screwdriver, install the dust seal in the groove in the piston.
8. Install the brake caliper. Refer to Rear Brake Caliper Replacement (J56) (Rear Brake Caliper Replacement (J56))Rear Brake Caliper Replacement (JL9-J55) (Rear Brake Caliper Replacement (JL9-J55)) .
9. Replace the brake pads if needed. Refer to Front Disc Brake Pads Replacement (J56) (Front Disc Brake Pads Replacement (J56))Front Disc Brake Pads Replacement (JL9-J55) (Front Disc Brake Pads Replacement (JL9-J55)) .