Rear Brake Caliper Overhaul (J56)

Rear 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: Plug the brake hose to prevent brake fluid leaks and contamination.


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 compressed air to the piston.




6. Remove the piston (1) from the caliper.
7. After the inboard and outboard piston has 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: Remove the brake pipe only if it is damaged and must be replaced.


10. Remove the brake pipe between the inboard and outboard pistons, if necessary.



Installation Procedure






Important: Hand install both brake pipe fittings before tightening to specification.


1. Install the brake pipe between the inboard and outboard pistons, if removed and hand start both brake pipe fittings.

Tighten the brake pipe fittings 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 groove.





Important: When the dust seal is properly seated, the dust seal maybe slightly above the surface of the caliper housing. 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 remainder of the caliper pistons.

6. Remove the brake caliper from the vise or holding fixture.

Important: Use care to avoid damage to the dust seal when installing into the caliper piston groove.


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 necessary. Refer to Rear Disc Brake Pads Replacement (JL9-J55) (Rear Disc Brake Pads Replacement (JL9-J55))Rear Disc Brake Pads Replacement (J56) (Rear Disc Brake Pads Replacement (J56)) .