Caliper

Single Piston

Disassembly

1. Remove the front disc brake caliper (2B121) assembly and brake shoe and lining (2001) from the vehicle as outlined. Place a cloth over the wheel cylinder piston (2196) before applying air pressure to prevent damage to the wheel cylinder piston .

2. Apply air pressure to the fluid port in the front disc brake caliper with Air Nozzle Assembly TOOL-7000-DE or equivalent to remove the wheel cylinder piston .

3. Inspect wheel cylinder pistons . Replace wheel cylinder pistons if scoring, nicks, corrosion, or signs of wear are present.
   
   
   
   
   

   Item	Part Number	Description
   1	—	Fiber Block
   2	—	Cloth
   3	2196	Wheel Cylinder Piston
   4	TOOL-7000-DE	Air Nozzle Assembly
   5	2B119	Front Disc Brake Caliper

4. Remove the dust boot from the front disc brake caliper assembly and discard it.

5. Remove the rubber piston seal from the wheel cylinder piston and discard it.

6. Inspect caliper bores and seal grooves. Replace front disc brake caliper if either bore is badly scored or corroded around the seal groove area.

7. Remove bleeder cap and wheel cylinder bleeder screw (2208).

8. Clean all parts with denatured alcohol.

9. Dry with filtered, unlubricated compressed air, blowing out all passages in front disc brake caliper and wheel cylinder bleeder screw.

Assembly

1. Install wheel cylinder bleeder screw and tighten to 15 Nm (132 lb-in).

2. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Ensure seal does not become twisted but is firmly seated in the groove.

3. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore.

4. Coat wheel cylinder piston with brake fluid, and install wheel cylinder piston in the cylinder bore. Use a wood block or other flat stock when installing wheel cylinder piston back into piston bore. Ensure wheel cylinder piston is not cocked. Spread the dust boot over the wheel cylinder piston as it is installed. Seat dust boot in piston groove.

5. Install the brake shoe and lining and front disc brake caliper over the front disc brake rotor (1125) as outlined.