Brake Caliper Overhaul Bendix Rail Slider
Disassembly Procedure
- Remove the brake fluid from the brake caliper.
- Clean the exterior of the brake caliper.
- Remove the pistons from the bore by directing compressed air in to the caliper brake fluid inlet in order to remove the pistons from the caliper bore.
- Pad the exterior of the brake caliper with a clean shop towel.
- Remove the heat shields (1).
- Remove the dust boots (2).
- Remove the piston seals from the groove in the caliper bore using a pointed piece of wood or plastic.
- Remove the brake caliper bleeder valve.
- Clean all of the parts in Brake Parts Cleaner .
- Blow out all of the passages in the brake caliper housing (5) and the brake caliper bleeder valve.
- Clean the brake caliper support rail surfaces with a wire brush.
- Inspect the support rail surfaces for rust or corrosion.
- Inspect the brake caliper housing for cracks or other damage. Replace the caliper housing if necessary.
- Inspect the outside diameter of the pistons for the following conditions:
- If you find any surface faults, replace the piston.
- Inspect the caliper bore for the following conditions:
- Polish out stains and minor corrosion from the caliper bore with crocus cloth.
- Clean the caliper bore after using the crocus cloth.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
Notice: Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the padding, it can be damaged.
Important:
• Use just enough air pressure in order to ease the pistons out
of the bore. • If only one piston is blown loose, it may be necessary to reinsert
the piston part way and block it in position. • Apply air pressure in order to free the remaining piston.
Notice: Do not use mineral base cleaning solvents such as gasoline, kerosene, carbon tetrachloride, acetone, or paint thinner to clean the brake caliper. These solvents will cause rubber parts to become soft and swollen in an extremely short time.
Use dry, filtered, unlubricated compressed air.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: The outside diameter of the piston is the primary sealing surface of the brake caliper. The piston diameter is manufactured to very close tolerances. Do not refinish the piston diameter. Do not use abrasives on the piston diameter.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: Do not use any abrasive on the caliper bore, including emery cloth.
If you cannot remove the stains and corrosion with crocus cloth, replace the caliper.
Assembly Procedure
- Place the brake caliper housing on a clean work bench with the open ends of the caliper bores facing up.
- Dip the new piston seal in Brake Fluid.
- Gently work the piston seal around the caliper bore with a finger until the seal seats in the piston seal groove.
- Ensure that the piston seal is not twisted or rolled in the groove.
- Lubricate the piston and the caliper bore with Brake Fluid.
- Gently push the piston into the caliper bore.
- Rotate the piston slightly in order to prevent dislodging the piston seal.
- Press the dust boot (2) into the counterbore in the brake caliper housing (5).
- Install a new heat shield (1) on the piston (3). The shield's chamfer faces out.
- Install the brake caliper bleeder valve.
The dust boot fits in a counterbore in the brake caliper housing, and overlaps the stepped edge of the piston.
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.
Tighten
Tighten the brake caliper bleeder valve to 17 N·m (13 lb ft).
Brake Caliper Overhaul Dayton-Walther Rail Slider
Disassembly Procedure
- Remove the brake fluid from the brake caliper.
- Clean the exterior of the brake caliper.
- Remove the pistons from the bore by directing compressed air in to the caliper brake fluid inlet in order to remove the pistons from the caliper bore.
- Pad the exterior of the brake caliper with a clean shop towel.
- Remove the heat shields (1).
- Remove the dust boots (2).
- Remove the piston seals from the groove in the caliper bore using a pointed piece of wood or plastic.
- Remove the brake caliper bleeder valve.
- Clean all of the parts in Brake Parts Cleaner.
- Blow out all of the passages in the brake caliper housing (5) and the brake caliper bleeder valve.
- Clean the brake caliper support rail surfaces with a wire brush.
- Inspect the support rail surfaces for rust or corrosion.
- Inspect the brake caliper housing for cracks or other damage. Replace the caliper housing if necessary.
- Inspect the outside diameter of the pistons for the following conditions:
- If you find any surface faults, replace the piston.
- Inspect the caliper bore for the following conditions:
- Polish out stains and minor corrosion from the caliper bore with crocus cloth.
- Clean the caliper bore after using the crocus cloth.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
Notice: Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the padding, it can be damaged.
Important:
• Use just enough air pressure in order to ease the pistons out
of the bore. • If only one piston is blown loose, it may be necessary to reinsert
the piston part way and block it in position. • Apply air pressure in order to free the remaining piston.
Notice: Do not use mineral base cleaning solvents such as gasoline, kerosene, carbon tetrachloride, acetone, or paint thinner to clean the brake caliper. These solvents will cause rubber parts to become soft and swollen in an extremely short time.
Use dry, filtered, unlubricated compressed air.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: The outside diameter of the piston is the primary sealing surface of the brake caliper. The piston diameter is manufactured to very close tolerances. Do not refinish the piston diameter. Do not use abrasives on the piston diameter.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: Do not use any abrasive on the caliper bore, including emery cloth.
If you cannot remove the stains and corrosion with crocus cloth, replace the caliper.
Assembly Procedure
- Place the brake caliper housing on a clean work bench with the open ends of the caliper bores facing up.
- Dip the new piston seal in Brake Fluid.
- Lubricate the caliper bore with Brake Fluid.
- Gently work the piston seal (4) into the caliper bore piston seal groove until the seal seats properly.
- Ensure that the piston seal is not twisted or rolled in the groove.
- Install a new dust boot (2) into the caliper bore.
- Install the piston through boot and into the bore.
- Install the brake caliper bleeder valve.
Important:
• Apply even force and slightly rotate the piston (3). This
avoids cocking the piston in the caliper bore and dislodging the piston seal. • The dust boot will slide into the piston. • Ensure that the dust boot seats evenly into the piston groove.
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.
Tighten
Tighten the brake caliper bleeder valve to 17 N·m (13 lb ft).
Brake Caliper Overhaul Bendix
Disassembly Procedure
- Remove the brake fluid from the brake caliper.
- Clean the exterior of the brake caliper.
- Remove the pistons from the bore by directing compressed air in to the caliper brake fluid inlet in order to remove the pistons from the caliper bore.
- Pad the exterior of the brake caliper with a clean shop towel.
- Remove the heat shields (1).
- Remove the dust boots (2).
- Remove the piston seals from the groove in the caliper bore using a pointed piece of wood or plastic.
- Remove the brake caliper bleeder valve.
- Clean all of the parts in Brake Parts Cleaner.
- Blow out all of the passages in the brake caliper housing (5) and the brake caliper bleeder valve.
- Clean the brake caliper support rail surfaces with a wire brush.
- Inspect the support rail surfaces for rust or corrosion.
- Inspect the brake caliper housing for cracks or other damage. Replace the caliper housing if necessary.
- Inspect the outside diameter of the pistons for the following conditions:
- If you find any surface faults, replace the piston.
- Inspect the caliper bore for the following conditions:
- Polish out stains and minor corrosion from the caliper bore with crocus cloth.
- Clean the caliper bore after using the crocus cloth.
Caution: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury.
Notice: Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the padding, it can be damaged.
Important:
• Use just enough air pressure in order to ease the pistons out
of the bore. • If only one piston is blown loose, it may be necessary to reinsert
the piston part way and block it in position. • Apply air pressure in order to free the remaining piston.
Notice: Do not use mineral base cleaning solvents such as gasoline, kerosene, carbon tetrachloride, acetone, or paint thinner to clean the brake caliper. These solvents will cause rubber parts to become soft and swollen in an extremely short time.
Use dry, filtered, unlubricated compressed air.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: The outside diameter of the piston is the primary sealing surface of the brake caliper. The piston diameter is manufactured to very close tolerances. Do not refinish the piston diameter. Do not use abrasives on the piston diameter.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: Do not use any abrasive on the caliper bore, including emery cloth.
If you cannot remove the stains and corrosion with crocus cloth, replace the caliper.
Assembly Procedure
- Place the brake caliper housing on a clean work bench with the open ends of the caliper bores facing up.
- Dip the new piston seal.
- Gently work the piston seal around the caliper bore with a finger until the seal seats in the piston seal groove.
- Ensure that the piston seal is not twisted or rolled in the groove.
- Lubricate the piston and the caliper bore with Brake Fluid.
- Gently push the piston into the caliper bore.
- Rotate the piston slightly in order to prevent dislodging the piston seal.
- Press the dust boot (2) into the counterbore in the brake caliper housing (5).
- Install a new heat shield (1) on the piston (3). The shield's chamfer faces out.
- Install the brake caliper bleeder valve.
The dust boot fits in a counterbore in the brake caliper housing, and overlaps the stepped edge of the piston.
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.
Tighten
Tighten the brake caliper bleeder valve to 17 N·m (13 lb ft).
Brake Caliper Overhaul Dayton-Walther
Disassembly Procedure
- Remove the brake fluid from the brake caliper.
- Clean the exterior of the brake caliper.
- Pad the exterior of the brake caliper with a clean shop towel.
- Direct compressed air in to the caliper brake fluid inlet in order to remove the pistons from the caliper bore.
- Remove the heat shields (1).
- Remove the dust boots (2).
- Remove the piston seals from the groove in the caliper bore using a pointed piece of wood or plastic.
- Remove the brake caliper bleeder valve.
- Clean all of the parts in Brake Parts Cleaner.
- Blow out all of the passages in the brake caliper housing (5) and the brake caliper bleeder valve.
- Clean the brake caliper support rail surfaces with a wire brush.
- Inspect the support rail surfaces for rust or corrosion.
- Inspect the brake caliper housing for cracks or other damage. Replace the caliper housing if necessary.
- Inspect the outside diameter of the pistons for the following conditions:
- If you find any surface faults, replace the piston.
- Inspect the caliper bore for the following conditions:
- Polish out stains and minor corrosion from the caliper bore with crocus cloth.
- Clean the caliper bore after using the crocus cloth.
Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
Notice: Use only enough air to ease the piston out of the bore. If the piston is blown out, even with the padding, it can be damaged.
| 4.1. | If only one piston leaves the bore, reinsert the piston part-way. |
| 4.2. | Block the reinserted piston in place. |
| 4.3. | Apply air pressure again. This should free the remaining piston. |
Notice: Do not use mineral base cleaning solvents such as gasoline, kerosene, carbon tetrachloride, acetone, or paint thinner to clean the brake caliper. These solvents will cause rubber parts to become soft and swollen in an extremely short time.
Use dry, filtered, unlubricated compressed air.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: The outside diameter of the piston is the primary sealing surface of the brake caliper. The piston diameter is manufactured to very close tolerances. Do not refinish the piston diameter. Do not use abrasives on the piston diameter.
| • | Scoring |
| • | Nicks |
| • | Corrosion |
| • | Wear |
| • | Any other damage |
Important: Do not use any abrasive on the caliper bore, including emery cloth.
If you cannot remove the stains and corrosion with crocus cloth, replace the caliper.
Assembly Procedure
- Place the brake caliper housing on a clean work bench with the open ends of the caliper bores facing up.
- Dip the new piston seal in Brake Fluid.
- Gently work the piston seal around the caliper bore with a finger until the seal seats in the piston seal groove.
- Ensure that the piston seal is not twisted or rolled in the groove.
- Lubricate the piston and the caliper bore with Brake Fluid.
- Gently push the piston into the caliper bore.
- Rotate the piston slightly in order to prevent dislodging the piston seal.
- Press the dust boot (2) into the counterbore in the brake caliper housing (5).
- Install a new heat shield (1) on the piston (3). The shield's chamfer faces out.
- Install the brake caliper bleeder valve.
The dust boot overlaps the stepped edge of the piston.
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.
Tighten
Tighten the brake caliper bleeder valve to 17 N·m (13 lb ft).
