Caliper Assembly

Tools Required:

• Rear Caliper Piston Adjuster T87P-2588-A
• Caliper Spring Compressor Set T87P-2588-B

Disassembly

1. Remove caliper assembly from vehicle as outlined.

2. Mount caliper in a vise. Use vise jaw protectors.

3. Using Rear Caliper Piston Adjuster T87P-2588-A, turn piston counterclockwise and remove piston from caliper piston bore.

4. Remove and discard piston dust boot seal and piston seal from caliper bore.

    CAUTION: The snap ring (circlip) and spring cover are under spring load and care should be taken when removing the snap ring (circlip).

5. With suitable snap ring (circlip) pliers remove snap ring (circlip) retaining push rod assembly from caliper.
   
   
   
   

6. From caliper bore, remove spring cover, spring, washer, key plate and pull out push rod and strut pin.

7. Remove and discard O-ring seal from push rod.

8. Remove parking brake lever return spring, unscrew parking brake lever stop bolt and pull parking brake lever out of caliper housing.

Cleaning and Inspection

1. Clean all metal parts with isopropyl alcohol. Use clean, dry compressed air to clean out and dry grooves and passages. Ensure caliper bore and component parts are completely free of any foreign material.

2. Inspect caliper bores for damage or excessive wear. If piston is pitted, scored or plating is worn off, replace piston assembly.

Assembly

1. Lightly grease parking brake lever bore and lever shaft seal with Silicone Dielectric Compound D7AZ-19A331-A (ESE-M1C171-A) or equivalent. Press parking brake lever shaft seal into caliper bore.

2. Grease parking brake shaft recess and slightly grease parking brake lever shaft. Insert shaft into bore in caliper housing.

3. Screw lever stop bolt into caliper housing. Tighten to 6-9 Nm (4.5-7 lb-ft). Attach parking brake lever return spring to stop bolt and insert free end into parking brake lever slot.
   
   
   
   

4. Install new O-ring seal in groove of push rod. Grease recess at push rod end with Silicone Dielectric Compound D7AZ-19A331-A (ESE-M1C171-A) or equivalent.

   NOTE: Tools used in Steps 6 through 9 are part of Caliper Spring Compressor Set T87P-2588-B.

5. Position strut pin into caliper housing and in recess of parking brake lever shaft. Insert push rod into push rod bore of caliper housing. Ensure pin is positioned correctly between shaft recess and recess at end of push rod. Place key plate over push rod so that locating nib fits into drilled locating hole in caliper housing. Install flat washer push rod spring and spring cover in order.
   
   
   
   

6. Insert outer spacer into piston bore.
   
   
   
   

7. Insert inner spacer into piston bore.
   
   
   
   

8. Place snap ring inside of inner spacer.
   
   
   
   

    CAUTION: Snap ring should "click" into place. Do not over-compress spring.

9. Position spring compressor and screw and cross-block on push rod, and lightly screw tool clockwise to compress spring. Install snap ring (circlip).
   
   
   
   

10. Install new piston seal in groove in caliper housing after lubricating seal with brake fluid C6AZ-19542-AA (ESA-M6C25-A) or equivalent.

    NOTE: Ensure one slot in piston face is positioned so it will engage with nib on brake pad shoe.

11. Coat piston and piston dust boot with clean brake fluid C6AZ-19542-AA (ESA-M6C25-A) or equivalent. Install dust boot into piston bore of caliper. Spread dust boot over piston and seat dust boot in piston groove. Rotate piston clockwise using Rear Caliper Piston Adjuster T87P-2588-A or equivalent until piston is fully seated.

12. Install caliper assembly as outlined.