Warning: On models equipped with ABS, before opening the hydraulic system, disconnect the battery and do not connect it until the bleed operation is completed and the reserve tank is filled with fluid. If this is not done, air can get into the ABS hydraulic system, which will require specialized diagnostic equipment to remove - you will have to contact your dealer for help.
Note: Before starting the procedure, read the warnings in paragraphs 2 and 5 about the harmfulness of asbestos dust and brake fluid.
Withdrawal
Note: New guide pin bolts are required for installation.
1. Place wedges under the front wheels, turn on the rear (or "R" in case of automatic transmission), raise the rear of the vehicle and install safety stands (see Jacking up the vehicle and installing jack stands). Remove the corresponding wheel. When removing the wheels, wrap one bolt into the hubs so that the brake discs do not mix relative to the hub.
2. As described in paragraph 15, release the handbrake, then release the cable adjustment "handbrake" so as to obtain maximum slack in the cables.
3. Disconnect the tip of the handbrake cable from the caliper operating lever, pull the cable sheath out of the caliper housing.
4. To minimize fluid loss, place a plastic circle under the lid of the reserve tank, creating an airtight seal (do not damage the sensor). You can clamp the brake hose closer to the caliper with a clamp.
5. Remove the dirt around the connection of the brake pipe with the caliper and unscrew the connecting nut. Carefully remove the tube and wrap the end with electrical tape to keep dirt out of the system. Wipe up spilled liquid immediately.
6. Turn out bolts of fastening of directing fingers of a support, holding fingers by a thin wrench. Discard the bolts - new ones are required for installation.
7. Remove a support from an arm of fastening and turn away it from a tip of a brake hose. Plug the hose and the hole in the caliper so that dirt does not get in and fluid does not spill in vain. Wash off the drunk liquid immediately with cold water. Remove the brake pads. Loosen the bolts and remove the caliper mounting bracket.
Repair
Note: The caliper hand brake mechanism cannot be repaired. If the mechanism is defective, or liquid oozes through the seal of its lever, the entire caliper must be replaced.
8. After placing the caliper on the workbench, clean it, but do not inhale the dust, as it is harmful to health.
9. Remove the piston by unscrewing it from the caliper counterclockwise with a screwdriver or square bar, inserting it into the cutouts on the piston. If the piston rotates freely, but no longer comes out of the caliper, it can be further removed by hand, since it is held by the seal alone.
10. With a non-sharp tool such as a plastic knife, remove the piston seal from the groove in the cylinder, being careful not to damage the cylinder itself.
11. Remove the guide bushings with covers from the caliper struts.
12. Inspect the caliper components as described in paragraph 10. Replace defective components with new ones (hand brake mechanism - collapsible).
13. Make sure all components are clean and dry.
Pic. 9.13. Components of the rear brake caliper: 1. Self-locking bolt; 2. Caliper; 3. Fitting for pumping; 4. cap; 5. Piston seal; 6. Piston; 7. Guide pin; 8. Anther; 9. Anther; 10. Caliper mounting bracket
14. Immerse the piston and new piston seal in clean brake fluid. Lubricate the surface of the cylinder with it. Install a new piston seal in the cylinder groove and install the piston.
15. Install a new dust boot in the caliper groove. Gently and evenly rotate the piston into the cylinder. Screw the piston into the cylinder clockwise until it stops and install the boot into the piston groove.
16. Apply the grease supplied with the repair kit or a good quality high temperature brake grease or non-stick compound to the guide bushings. Install the bushings on the caliper and install new boots by tucking them into the groove on the caliper and bushings.
17. Before installation, fill the caliper with fresh brake fluid by loosening the bleeder plug and bleed the cylinder until bubbles stop coming out of the bleeder.
Installation
18. Install the caliper bracket and secure with new bolts, tightening them to the prescribed torque (pic. 9.18). Install the brake pads as described in paragraph 5.
19. Wipe clean the brake pipe connection. Install the caliper on the brake hose connection, screw it on and install the caliper on the disc. Install new guide pin bolts to the specified torque.
20. Remove the clamp from the brake hose or remove the polyethylene from under the reservoir cap.
21. Bleed the hydraulic system as described in paragraph 2. Perhaps it will be enough to pump only one disturbed circuit.
22. Attach the end of the cable to the operating lever, securing it with a retainer and adjust the cable as described in paragraph 16.
23. Mount the wheel, lower the vehicle and tighten the wheel bolts to the prescribed torque as described in chapter 1A or 1B.
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