Special Tools

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

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

Note: The brake pads must be removed to remove the brake caliper of the rear wheel brake.

1. Release the parking brake cable.

•	Release the parking brake lever.

•	Remove the parking brake bellows.

•	Release the parking brake cable by unscrewing the adjusting nut.

2. Top up the brake fluid the reservoir to the MAX marking and seal. Refer to Master Cylinder Reservoir Filling.

Note: Mark the position in relation to center of wheel.

3. Remove the appropriate rear wheel. Refer to Tire and Wheel Removal and Installation.



4. Release the brake caliper.

•	Remove the parking brake cable.

-	Push down the brake caliper actuation lever with a screwdriver and remove the parking brake cable.

-	Pull off the locking plate (3).

-	Draw the parking brake cable out of the mounting on the brake caliper.

•	Unscrew 1 screw (1).

Hold against the hexagon of the guide pin (2).

•	Fold the brake caliper upwards.





Note: 

•	Brake fluid rises in the reservoir, if necessary siphon with siphon bottle.

•	The collar of KM-6007-30 must point in the direction of the hand wheel or hexagonal section of KM-6007 .

5. Unscrew the brake piston.

Turn the brake piston back with KM-6007  (1) and KM-6007-30  (2).

•	Turn the piston back to stop.

•	Screw the piston outwards again until the next cut-out in the brake piston is aligned with the opening on the brake caliper (arrows).





Note: The brake caliper must be completely removed from the brake carrier before mounting the brake pads.

6. Remove the brake caliper from the brake support.

•	Unscrew the bolt (1).

Hold against the hexagon of the guide pin (2).

•	Remove the brake caliper from the brake carrier.

•	Suspend the brake caliper from the rear spring with a suitable wire.

7. Remove the brake pads and the guide plates.




Note: Collect the escaping brake fluid and seal aperture.

8. Remove the brake hose (1) from the brake caliper.
9. Remove the bolts (3) for the brake carrier (2) from the brake backing plate and remove the brake carrier.

1. If the brake caliper leaks, the protective cap on the brake caliper is damaged or the brake carrier sealing sleeve is damaged, replace the brake caliper/brake carrier. Refer to Rear Brake Caliper Replacement.

Caution: Refer to Fastener Caution in the Preface section.





Note: Clean thread and insert bolts with locking compound.

2. Install the brake caliper to the brake carrier plate.

Tighten
Tighten the bolt to 100 N·m (74 lb ft).

3. Install the brake pads with new adhesive film. Refer to Rear Disc Brake Pad Attachment Replacement.
4. Install the parking brake cable to the bracket with a new retaining clamp (3).

•	Press the actuating lever (2) downwards with a screwdriver.

•	Attach the parking brake cable.

5. Install the brake hose (1) to the brake caliper with new seal rings.

Tighten
Tighten to 40 N·m (30 lb ft).

6. Install the rear wheel. Refer to Tire and Wheel Removal and Installation
7. Lower the vehicle.
8. Bleed the brake system and check for leaks. Refer to Hydraulic Brake System Bleeding.
9. Actuate the brake pedal repeatedly.
10. Top up the brake fluid to the MAX mark. Refer to Master Cylinder Reservoir Filling.
11. Adjust the parking brake. Refer to Parking Brake Adjustment.