Girling Brake Caliper Parts
1 Brake hose
2 Mounting bracket
3 Brake pipe, 5 Nm
4 Self-locking bolt, 30 Nm
5 Ribbed bolt, 125 Nm
6 Carrying support
7 Brake disc
8 Brake pads
9 Heat-protective casing
10 Caliper cylinder
11 Holder, bolted to the caliper body
12 Bolt, 10 Nm. The caliper carrier (6) is supplied with guide pins and protective caps
ATE brake caliper parts
1 Protective caps
2 Guide pins
3 Screw (valve) for air removal
4 Dust cap
5 Brake cylinder housing
6 Fastening spring
7 Plastic bushing
8 Carrying support
9 Cylinder cuff
10 Piston
11 Protective cap
Disassembled Girling caliper
1 Dust cap
2 Air bleed screw
3 Caliper cylinder
4 Self-locking bolt, 30 Nm, replace
5 Cylinder cuff
6 Piston
7 Dust ring
8 Carrying support with guide pin and protective cuff
Repair of brake calipers of both designs is carried out in similar ways. Calipers can be replaced independently only under the following conditions:
If you have some experience in handling brake system components.
If you have a repair kit for brake calipers. Since it is necessary to remove air from the brake caliper after repair, you should prepare a device for removing air without the help of an assistant. Otherwise, it is difficult to pump fluid through the caliper.
The following instructions are given for both caliper designs:
Clamp the cylinder in a vice and use a screwdriver to remove the dust ring from the cylinder and piston.
Place a piece of wood in the recess in front of the piston and use compressed air to push the piston out of the cylinder bore.
Using a screwdriver, carefully pry the sealing ring (cuff) from the inside of the cylinder bore without damaging the bore.
Clean all parts thoroughly and, if the cylinder is in good condition, use the parts from the repair kit during assembly. It is necessary to select a repair kit in accordance with the year of manufacture of the car.
Lubricate the new cuff with brake fluid or special grease and install it.
Place the dust ring with the outer sealing edges on the piston and lubricate the piston surface with brake fluid or special grease.
Push the piston into the cylinder and place the inner sealing lips of the dust ring on the cylinder, then install the piston. A small screwdriver is used for this. The caliper is clamped in a vice.
Using a clamp, slowly press the piston into the cylinder bore. The outer sealing lips of the dust ring will snap into the groove of the piston when they are opposite them.
Now you need to first remove the air from the caliper. If there is a special device for removing air alone, then put the hose on the screw (valve) for removing air and unscrew the valve. Pump brake fluid from the device until it starts to come out of the hole for the brake hose. In this case, the caliper should be in the position shown in the figure.
(Text provided by the online resource: «AudiManual.ru»)