Caliper FN3
Attention! It is not recommended to carry out the bulkhead of the caliper yourself. It is better to entrust this work to the workshop, delivering the caliper assembly.
1. Fix the removed caliper in a vise by placing a wooden block on the opposite side of the cylinder to prevent damage to the piston when it is pushed out with compressed air, and press the piston together with the cuff from the cylinder with compressed air (see illustration).
8.1. Fix the removed caliper in a vice and press the piston together with the cuff from the cylinder with compressed air
2. Remove the piston sealing ring from the cylinder by prying it with a plastic wedge (see illustration).
8.2. Remove the piston o-ring from the cylinder by prying it with a plastic wedge
3. Inspect the brake caliper. If there is rust or grooves on the inner wall of the brake cylinder, then the caliper must be replaced with a new one.
4. Install a new O-ring into the groove inside the cylinder bore, lubricating the piston and O-ring with G052150A2 grease.
5. Put the cuff on the piston (see illustration).
8.5. Put the cuff on the piston
6. Place the piston on the cylinder bore and, taking some care to prevent crushing of the piston, insert the working edge of the seal into the groove on the cylinder bore with a plastic wedge (see illustration).
8.6. Insert the working edge of the cuff into the groove on the cylinder channel with a plastic wedge
7. Do not fully sink the inserted piston, because in this case it will not be possible to get the protrusion on the cuff into the groove on the piston.
8. Press the piston into the cylinder cavity with the appropriate tool (see illustration).
8.8. Press the piston into the cylinder cavity with the appropriate tool
Caliper FNR-G60
9. It is not recommended to rebuild the caliper yourself. It is better to entrust this work to the workshop, delivering the caliper assembly.
10. Secure the removed caliper in a vise by placing a wooden block on the opposite side of the cylinder to prevent damage to the piston when it is pushed out with compressed air, and press the piston out of the cylinder with compressed air (see illustration).
8.10. Secure the removed caliper in a vice and press the piston out of the cylinder with compressed air
11. Remove the piston sealing ring from the cylinder by prying it with a plastic wedge (see illustration), and a protective cuff.
8.11. Remove the piston o-ring from the cylinder by prying it with a plastic wedge
12. Install a new O-ring into the groove inside the cylinder bore, lubricating the piston and ring with G052150A2 grease (see arrow in illustration).
8.12. Install a new O-ring into the groove inside the cylinder bore (see arrow)
13. Fill the inner end of the cuff into the cylinder channel, and then press the cuff into the cylinder with tool 2, putting a protective pad 1 on it (see illustration).
8.13. Insert the inner end of the cuff into the cylinder channel, and then press the cuff into the cylinder with tool 2, placing a protective pad 1 on it
14. Make sure the cuff is firmly seated in place and will not come off when tightened by hand (see illustration).
8.14. Make sure the cuff is firmly seated in place and does not come off when tightened by hand
15. Insert the piston into the opening of the cuff and push it in a little with a suitable tool 1 (see illustration).
8.15. Insert the piston into the hole in the cuff and push it in a little with a suitable tool 1
Attention! Perform this operation carefully to avoid misalignment of the piston and damage to the cuff.
16. Supply compressed air through the hole for the bleeder valve 2 (Max. 3 bar), while holding the piston so that the cuff moves onto the piston under air pressure (see illustration 8.15).
17. Push the piston into the cylinder bore by hand. In this case, the outer belt of the cuff will go into the groove on the piston.
Caliper HP2
18. Unscrew the bleed fitting from the dismantled caliper and apply compressed air through the opening for the fitting to press the cylinder pistons.
Attention! The pistons are pressed out one by one. One is blocked by a pressing tool «b», and opposite the second one a wooden block is installed «A» (see illustration).
8.18. Press out both pistons in turn, supplying compressed air through the hole for the bleeder fitting
19. Remove the piston o-rings from the cylinders by prying them with a plastic wedge, for example, AUDI 3409 (see illustration).
8.19. Remove the piston o-rings from the cylinders by prying them with a plastic wedge
20. Lubricate the pistons and o-rings with a thin layer of grease G052150A2 before assembling, cleaning them before this alcohol.
21. Install the O-rings in their positions in the cylinders.
22. Put on the piston sealing cuff (see illustration).
8.22. Put the seal on the piston
23. Insert the inner collar of the piston collar into the cylinder cavity with a plastic wedge, holding the piston near the cylinder bore (see illustration).
8.23. Insert the inner collar of the piston collar into the cylinder cavity using a plastic wedge
24. Push the piston into the cylinder cavity by hand, and then with a pressing tool. In this case, the outer belt of the cuff will go into the groove on the piston.
Caliper Brembo 18"
25. Unscrew the bleeder fitting from the dismantled caliper and apply compressed air through the hole for the fitting to press out the cylinder pistons.
Attention! The pistons are pressed out one by one. The piston opposite the one to be pressed out is blocked by the pressing tool «A», and the rest - with wooden bars «b». Place a piece of wood in front of the pressing tool to prevent damage to the piston being removed (see illustration).
8.25. Press out all the pistons one by one by supplying compressed air through the hole for the bleeder fitting
26. Remove the piston o-rings from the cylinders by prying them with a plastic wedge, for example, AUDI 3409 (see illustration).
8.26. Remove the piston o-rings from the cylinders by prying them with a plastic wedge
27. Lubricate the pistons and o-rings with a thin layer of grease G052150A2 before assembling, cleaning them before this alcohol (see illustration).
8.27. Lubricate the pistons and o-rings with a thin layer of grease before assembly
28. Install the O-rings in their positions in the cylinders.
29. Put cuffs on the pistons (see illustration).
8.29. Put cuffs on the pistons
30. Press the piston into the cylinder with your fingers until the piston collar fits in the cylinder groove (see illustration). If necessary, press the piston with a pressing device.
8.30. Press the piston into the cylinder with your fingers until the piston collar fits into the cylinder groove
Caliper С38/С43
31. Unscrew the piston from the cylinder using press tool B by turning it to the left and handle A to the right (see illustration).
8.31. Unscrew the piston from the cylinder using press tool B by turning it to the left and handle A to the right
32. Remove the piston o-ring by prying it with a plastic wedge (see illustration).
8.32. Remove the piston o-ring by prying it with a plastic wedge
33. Lubricate the piston and o-ring with a thin layer of grease G052150A2 before assembling, cleaning them before this alcohol.
34. Install the O-ring in its place in the cylinder.
35. Put on the piston sealing cuff (see illustration).
8.35. Put the seal on the piston
36. Insert the inner collar of the piston collar into the cylinder cavity with a plastic wedge, holding the piston near the cylinder bore (see illustration).
8.36. Insert the inner collar of the piston collar into the cylinder cavity using a plastic wedge
37. Screw the piston into the cylinder using press tool B by turning it to the right and handle A to the left.
38. Fill the wheel cylinder with brake fluid to remove air. The liquid should be filled through the bleeder valve until the liquid exits through the opening of the brake pipeline without air bubbles (see illustration).
8.38 Fill the wheel cylinder with brake fluid to remove air from it
Visitor comments