Front Brake Caliper Overhaul Base and GT

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

Note: 

1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement.
2. Drain the brake fluid from the brake caliper.




Note: To remove the guide pin bolts (8) use a suitable tool to hold the flat section on the guide pins (6) while loosening the guide pin retaining bolts (8).

3. Remove the guide pin retaining bolts (8).
4. Separate the brake caliper housing (7) from the brake caliper anchor plate (4).
5. Remove the brake pads (1 and 3).
6. Remove the retainer clips (2).
7. Withdraw the guide pins (6) and dust boots (5) from the brake caliper anchor plate (4).

Separate the dust boots (5) from the guide pins (6).





Warning: 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.

Caution: 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.

Note: Observe the pistons coming out of the bores. If one of the pistons appears to be seized, STOP applying air pressure.

8. Remove the brake caliper pistons by directing low pressure compressed air into the brake caliper inlet hole.

If one of the pistons appears to be seized, perform the following steps:

8.1.	Place a 25 mm (1 in) block of wood between the brake caliper and the brake caliper piston that was moving freely.

Note: Position the ends of the G-clamp against the rear of the brake caliper and against the 25 mm (1 in) block of wood.

8.2.	Install a large G-clamp over the body of the brake caliper.

8.3.	Remove the brake seized caliper piston by directing low pressure compressed air into the brake caliper inlet hole.

8.4.	Remove the G-clamp from the brake caliper.

8.5.	Remove the block of wood from the brake caliper.

9. Install clean workshop cloths (1) to pad the interior of the brake caliper (3) between the remaining brake caliper piston and the body of the brake caliper (3).
10. To cover the open brake caliper bore place a 25 mm (1 in) block of wood (2) between the body of the brake caliper (3) and the brake caliper dust boot seal.

Note: Position the ends of the G-clamp against the rear of the brake caliper (3) and against the 25 mm (1 in) block of wood (2).

11. Install a large G-clamp over the body of the brake caliper (1).
12. Remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole.
13. Remove the G-clamp from the brake caliper (3).
14. Remove the block of wood (2) from the brake caliper (3).




Note: Use a small wooden or plastic tool to avoid damage to the brake caliper (1).

Note: Brake caliper seals are single use components only and must be discarded after removal.

15. With the brake caliper pistons (4) removed, remove the brake caliper piston dust boot seal (3) from the brake caliper (1).

Discard the brake caliper piston dust boot seal (3).

16. Remove the brake caliper piston seal (2) from the brake caliper (1).

Discard the brake caliper piston seal (2).

17. Remove the brake caliper bleeder valve (6).
18. Inspect the brake caliper anchor plate guide surfaces for corrosion and wear.

Replace the brake caliper assembly if damaged or worn.

19. Clean the brake caliper piston bores (5) with denatured alcohol, or equivalent.

Note: DO NOT use abrasives to clean the brake caliper assembly.

20. Clean the brake caliper pistons (4) with denatured alcohol, or equivalent.
21. Clean the brake caliper bleeder valve (6).
22. Dry the brake caliper piston bores (5) with non-lubricated, filtered air.
23. Dry the brake caliper pistons (4) with non-lubricated, filtered air.
24. Dry the brake caliper bleeder valve (6) with non-lubricated, filtered air.
25. Inspect the brake caliper bores (5) for cracks, scoring, pitting, too much corrosion.

If cracks, scoring, pitting, and too much corrosion are present in the brake caliper bores (5), replace the brake caliper assembly.

26. Inspect the brake caliper pistons (4) for cracks, scoring, and/or damage.

If cracks, scoring, and/or damage are present in the brake caliper pistons (4), replace the brake caliper pistons (4) if any of these conditions exist.

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Warning: Refer to Brake Dust Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

Note: 

Caution: Refer to Fastener Caution in the Preface section.




1. Install the brake caliper bleeder valve (6) and tighten to 12 N·m (106 lb in).
2. Lubricate the NEW brake caliper piston seals (2) with Super DOT 4 or DOT 4 Plus brake fluid from a clean, sealed brake fluid container.

Note: When installing, make sure the brake caliper piston seals (2) are not twisted.

3. Install the brake caliper piston seals (2) into the seal grooves in the brake caliper bores (5).
4. Lubricate the brake caliper bores (5) and pistons (4) with brake fluid.
5. Install the brake caliper pistons (4) into the caliper bores (5).
6. Install the NEW brake caliper piston dust boot seals (3) over the brake caliper pistons (4).
7. Complete the following for both brake caliper piston dust boot seals (3).

7.1.	Fully seat the brake caliper piston dust boot seal (4) into the brake caliper (1).

7.2.	Make sure the brake caliper piston dust boot seal (4) is correctly seated into the groove in the brake caliper bore (5).




8. Lubricate the guide pins (6) with silicone grease, such as Dow Corning No. 44 or equivalent.
9. Install guide pins (6) into the brake caliper anchor plate (4).

Do not fit the two guide pin boots (5) at this stage.

Note: To install the guide pin bolts (8) use an open-end spanner to hold the flat section on the guide pins (6) whilst installing the guide pin bolts (8).

10. Install the brake caliper (7) to the brake caliper anchor plate (4) and install NEW guide pin bolts (8). Tighten the guide pin bolts to 42 N·m (31 lb ft).

Note: Make sure that the brake caliper (7) and guide pins (6) slide in and out easily from the brake caliper anchor plate (4). If any binding is evident, then steps 8 and 9 must be repeated.

11. Detach the brake caliper (7) from the brake caliper anchor plate (4) and install the NEW guide pin boots (5) to the guide pins (6).
12. Install the brake pad retainers (2) to the brake caliper anchor plate (4).

Note: The brake pads (1 and 3) are marked as inner and outer only. Failure to install the front brake pads (1 and 3) in their correct position will cause the brake pads (1 and 3) not to seat correctly in the brake caliper (7).

13. Install the brake pads (1 and 3) to the brake caliper anchor plate (4).

Note: Remove all excess air from the guide pin boot (5) and make sure that each guide pin boot (5) is correctly located in the grooves in the guide pin (6) and brake caliper anchor plate (4).

14. Assemble the brake caliper (7) and brake caliper anchor plate (4) together.
15. Install the brake caliper assembly to the vehicle. Refer to Front Brake Caliper Replacement.