Pic. 242. Brake caliper installation drawing 1. Dust cuff; 2. Spacer sleeve; 3. Bushing; 4. Piston; 5. Piston collar; 6. Dust ring; 7. Retaining ring
- Clamp the brake caliper cylinder in a vice.
- Place a small screwdriver under the end of the retaining ring (7) and pull out the ring (Pic. 243)
Fig. 243. Removing the boot retaining ring. The boot ring is removed in a similar way.
- Also, use a screwdriver to remove the dust protection ring (6). (Pic. 243). Carry out both jobs carefully so as not to damage the brake caliper.
- In order to pull the piston out of the cylinder, you must have a line of compressed air. Before connecting the compressed air line, place a thick cloth between the cylinder and the piston. Under no circumstances should you place your fingers near the place where the piston will be blown out with compressed air. Compressed air is connected to the brake hose fitting, as shown in Figure 244.
Pic. 244. Blowing the piston out of the cylinder bore.
- Using a blunt instrument, pull out the cuff (5) piston from cylinder groove (Pic. 245), without scratching the cylinder mirror. If scratches, burrs or other damage is found in the bore, replace the entire cylinder. Small surface irregularities can be removed with fine sanding paper. Do not treat the contact surface of the piston with fine sandpaper. The cuff and dust ring of the cylinder must be replaced. Both rubber dust caps (1) in the cylinder, as well as the sliding bushings are replaced.
Pic. 245. Pulling the cylinder cuff out of the brake caliper.
- When assembling, lubricate all internal parts with brake fluid or brake grease and then assemble the brake caliper cylinder as follows:
- Lubricate the new cuff (5) brake fluid and insert into the cylinder bore. Use your fingers to press the cuff into the groove.
- Press the piston into the hole. The open side of the piston faces outward. Be sure to ensure that the piston enters without distortion. Under no circumstances should force be applied to the piston.
- Lubricate the new dust ring (6) brake fluid or brake grease and place in the cylinder
- Lubricate the cylinder mounting bushings with rubber grease and press the first bushing into the cylinder until it slides into the groove. Also lubricate the spacer tube with rubber lubricant, insert it into the rubber bushing and press the bushing from the opposite side until it presses into the groove.
- Check the cleanliness of the brake caliper again before installing it.