SECTION VI BRAKES
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Reassembling Calipers, continued
Š SA 20 M 12 PL Jo E ne C s H & AP B TE art R let O tL N ea LY r n
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SKILL DRILL
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If the brake pedal is spongy, you will need to bleed the brakes of any remaining trapped air in the system.
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Inspect the system for any brake fluid leaks, no matter how small.
ring, piston, and any other moving parts. Be careful to not pinch, twist, or cut the sealing ring and dust boot. (Step 2) Assemble the pads, hardware, and caliper on the caliper mountings using the specified lubricant. (Step 3) Reinstall the brake line fittings using two new copper washers (if equipped). Place one between the brake line fitting and the head of the banjo bolt and the other between the brake line fitting and the caliper. (Step 4) Tighten the brake line fitting and the caliper mounting bolt(s) to the proper torque. Bleed the brakes following the manufacturer’s procedure. See the brake bleeding skill drills in the Hydraulics and Power Brakes chapter for more information. (Step 5) Seat the pads by applying the brake pedal several times. It is a good idea to place your left foot under the brake pedal so that when applying the pedal with your right foot, the pedal does not push the master cylinder pistons farther into the master cylinder bore, which could dislodge sludge or cut the lips of the master cylinder primary seals. Applying the brake will force the brake caliper pistons to adjust to the proper clearance for proper
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brake application. You may need to start the vehicle to enable the power booster to help you fully apply the brakes, especially if the vehicle is equipped with integrated parking brake calipers. (Step 6) If the brake pedal is spongy, you will need to bleed the brakes of any remaining trapped air in the system. (Step 7) If the brake pedal is firm and does not sink over time, there could still be a small leak that would cause a future brake failure. Inspect the system for any brake fluid leaks, no matter how small; if found, inform your supervisor/instructor. (Step 8)
Retracting and Readjusting Pistons on an Integrated Parking Brake Retracting the caliper piston on an integrated parking brake system is different than on a standard caliper. Since the integrated parking brake system uses a threaded shaft to force the piston outward from the caliper bore, it cannot just be retracted with a C-clamp. The piston will need to be screwed back in on the threaded shaft to retract it into the bore. This is accomplished by using a tool that mates to slots, grooves, or holes in the outer face of the piston. The tool is then turned by hand or wrench to screw the piston back into the bore. Be careful to not tear the piston dust boot during this operation.