Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

Notice: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result.

Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

1. Remove the caliper. Refer to Front Brake Caliper Replacement .



2. Remove the pistons. Blow compressed air into the caliper inlet hole. The piston will come out through the piston boots.
3. Inspect the pistons for the following conditions. Replace the pistons as necessary:

•

Scoring

•

Nicks

•

Corrosion

•	Worn or damaged chrome plating




4. Remove the piston boots (1). Do not scratch the housing (2) bores.



5. Remove the piston seals (5) from the grooves in the caliper bores (4). Use a small wooden or plastic tool.
6. Inspect the caliper bores and the seal grooves for the following conditions:

•

Scoring

•

Nicks

•

Corrosion

•

Wear

7. Use a crocus cloth in order to polish out light corrosion.
8. Replace the caliper housing (1) if the corrosion that is in and around the seal groove cannot be cleaned with a crocus cloth.



9. Inspect the pin boots (5) for the following conditions:

•

Cuts

•

Tears

•	Deterioration

10. Replace any damaged boots.
11. Inspect the pin bolts (1) for corrosion or damage.
12. Replace any corroded bolts. Do not attempt to polish away corrosion.
13. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged.
14. Remove the bleeder valve cap (2) and the bleeder valve (3) from the caliper housing (4).
15. Clean all the parts in clean, denatured alcohol.
16. Dry all the parts with filtered, non-lubricated compressed air.
17. Blow out all the passages in the caliper housing and the bleeder valve with filtered, non-lubricated compressed air.

Tools Required

J 36349 Front Dust Boot Seal Installer

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the bleeder valve (3) into the caliper housing (1).

Tighten
Tighten the bleeder valve to 13 N·m (11 lb in).

2. Install the bleeder valve cap (2) onto the bleed valve.
3. Install new, lubricated piston seals (5) into the caliper bore grooves. Ensure that the piston seals are not twisted.



4. Install the lubricated boots (1) onto the pistons (2).
5. Lubricate the piston ODs with clean brake fluid.



6. Install the pistons (6) and the boots (7) into the bores (4) of the caliper. Push the pistons into the bottom of the bores.



7. Seat the caliper boots in the caliper housing counterbores using the J 36349 .



8. Install the caliper (1). Refer to Front Brake Caliper Replacement .