2. Install the clamp on the brake high pressure line to the brake caliper.
3. Remove the brake pads as described in Chapter 3.
4. Unscrew the hollow bolt that secures the high-pressure brake line pipe to the caliper and remove the two copper gaskets (photo).
5. Use a screwdriver to pry up the caps of the caliper mounting bolts (photo).
6. With a socket wrench, unscrew the mounting bolts and remove the caliper from the steering knuckle.
7. Clean the outer surfaces of the caliper.
8. Use a lever to remove the outer plastic caps of the sliding sleeves.
9. Remove the dust cap from the caliper and piston using a lever.
10. Press the sliding sleeves slightly inward and remove the caps from their grooves.
11. Remove sliding sleeves, but note their locations.
12. Place a bar inside the caliper in place of the brake disc pads, then using air pressure from the air line or foot pump through the fluid inlet, gently pry the piston out of the cylinder. Remove the piston.
13. Unscrew the shield.
14. Use a lever to remove the piston seal from the cylinder, being careful not to scratch the surface.
15. Clean piston and cylinder with methanol and allow to dry. Examine the piston and cylinder bore surfaces for wear, damage and corrosion. If defects are evident, replace the entire caliper, however, if the surfaces are in good condition, use a repair kit that includes the piston seal and dust cap. Also buy a tube of brake cylinder paste.
16. Cover with a small amount of paste the contact point of the brake cylinder to the piston, cylinder bore and piston seal.
17. Position the piston seal in the cylinder groove, then carefully insert the piston until it engages the insulation. It may be necessary to rotate the piston to prevent this pinching in the insulation.
18. Loosen the dust cap in the piston groove, then press it into the caliper using a suitable length of metal tube.
19. Install the shield and tighten the bolts with a tightening torque regulated specification.
20. Check sliding sleeves for wear and condition of insulation.
21. Insert the sliding sleeves into the caliper.
22. Mount the inner sockets on the sliding sleeves and push them onto the caliper using a suitable length of metal tubing.
23. Install the outer heads on the sliding sleeves in the same way.
24. To install the caliper, place it on the steering knuckle, insert the mounting bolts and tighten them with a tightening force regulated specification.
25. Install the plastic caps on the mounting bolts.
26. Using new copper gaskets, insert the bolt through the hole in the connection of the high pressure line pipe of the brake system and tighten with a tightening torque regulated specification.
27. Check up that the support moves freely sliding couplings.
28. Install the brake shoes, in accordance with Chapter 3.
29. Remove the brake high-pressure line clamp or protective polyethylene cover and bleed the hydraulic system as described in Chapter 13. If there was no loss of brake fluid, it is enough to bleed the caliper that was removed, however, if the brake fluid has leaked out, bleed the entire system.
30. Install the wheel and lower the vehicle to the ground.
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