Front Brake Caliper Overhaul (J56, J57)

Front Brake Caliper Overhaul (J56, J57)

Special Tools

CH-47954 - Caliper Seal Installer

Removal Procedure

Warning:
Refer to Brake Dust Warning Brake Dust Warning.


Warning:
Refer to Brake Fluid Irritant Warning Brake Fluid Irritant Warning.


1. Remove the front brake caliper. Refer to Front Brake Caliper Replacement (J57) Front Brake Caliper Replacement (J57)Front Brake Caliper Replacement (JL9, J55) Front Brake Caliper Replacement (JL9, J55)Front Brake Caliper Replacement (J56) Front Brake Caliper Replacement (J56).

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

2. Install the caliper in a vise.





3. Position a tool between the inner and outer brake pads to prevent the remaining brake caliper pistons from being forced from the caliper bores.

4. Using the C-Clamp from the CH-47954 - Caliper Seal Installer, hold the brake pad opposite the piston to be removed from the caliper.

5. Apply filtered, non lubricated compressed air to the brake hose fitting inlet port.





6. Remove the piston (1) from the caliper.

7. After opposing inboard and outboard pistons have been removed, repeat Steps 3-6 for the remaining brake caliper pistons.

8. Using a plastic tool, carefully remove the dust seal (2) from the caliper body.

9. Using a plastic tool, carefully remove the piston seal (3).





Note:
Do not remove the brake caliper brake fluid transfer pipe unless the brake pipe is damaged and requires replacement.

10. Remove the brake caliper brake fluid transfer pipe, if necessary.

Installation Procedure

Caution:
Refer to Fastener Caution Fastener Caution.





Note:
Hand install the brake pipe fittings completely before tightening.

1. Install the brake caliper brake fluid transfer pipe, if removed and tighten the brake pipe fittings to 40 Nm (30 lb ft).





2. Install the piston (1), the dust seal (2), and the piston seal (3) in the brake caliper piston bore.





Note:
When the brake caliper piston dust seal is properly installed, the seal may protrude slightly above the surface of the brake caliper. This is a normal condition due to the slight curvature of the brake caliper.

3. Using the CH-47954 - Caliper Seal Installer, install the dust seal:

1. Position the C-Clamp and cup on the caliper.

2. Align the tool on the dust seal to ensure correct installation of the dust seal.

3. Using the C-clamp, slowly apply pressure to the dust seal.

4. Check the alignment of the dust seal to the brake caliper 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 the above procedure for the remaining dust seals.

4. Remove the brake caliper from the vise.

Note:
Do not damage the dust seal.

5. Using a small plastic tool, position the dust seal in the groove of the brake caliper piston.

6. Install the front brake caliper. Refer to Front Brake Caliper Replacement (J57) Front Brake Caliper Replacement (J57)Front Brake Caliper Replacement (JL9, J55) Front Brake Caliper Replacement (JL9, J55)Front Brake Caliper Replacement (J56) Front Brake Caliper Replacement (J56).