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- a.JPG (32.98 KiB) Viewed 9758 times
With an Allen key unwind the adjuster until you feel it has come away from the worm drive within the calliper. This is done by turning in a clockwise direction.
- rc1.JPG (31.4 KiB) Viewed 9758 times
Once this is done then you can pull the piston from the housing. If it's a bit stubborn then you can shift it by using an air hose as shown below. If you do this make sure your hand is ready to stop the piston from shooting out & getting damaged. I found short blasts were best.
- rc2.JPG (26.19 KiB) Viewed 9758 times
- rc3.JPG (24.32 KiB) Viewed 9758 times
Then remove the dust rubber cover.
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- rc5.JPG (25.64 KiB) Viewed 9758 times
Now remove the seal within the chamber.
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- rc7.JPG (26.32 KiB) Viewed 9758 times
Now you'll need a long slim pair of cir-clip pliers to remove the cir-clip inside the chamber .
I tried to find a pair but couldn't find any. So a little tip. If you buy the Draper cheap ones then you can drill two additional holes which makes them long enough to reach the clip.
Before I drilled.
- rc9.JPG (14.77 KiB) Viewed 9758 times
And after, showing the two new holes. This will make things a lot easier.
- rc10.JPG (20.7 KiB) Viewed 9758 times
Now remove the cir-clip at the bottom of the chamber which holds the worm drive in place.
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Remove the worm drive.
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Also the little pin located behind it.
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Now you can remove the hand brake lever.
- rc14.JPG (25.58 KiB) Viewed 9758 times
Now you'll need to wash & clean out the calliper body including all the areas where the new rubbers are to go. I finished by blowing the unit out with an air-gun just to make sure there was no debris left at all.
- rc15.JPG (26.21 KiB) Viewed 9758 times
Also clean the piston & other moving parts. I used flour paper as this will not damage any of the surfaces.
- rc16.JPG (25.81 KiB) Viewed 9758 times
Also remove the rubber on the end of the worm drive.
- rc17.JPG (25.5 KiB) Viewed 9758 times
Now you have cleaned everything you are ready to put back together. Note: these are new rubbers and not the original old ones.
- rc18.JPG (34.58 KiB) Viewed 9758 times
Fit the new seal to the end of the worm drive.
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Also the inner seal.
- rc20.JPG (35.07 KiB) Viewed 9758 times
Make sure its sitting correctly.
- rc21.JPG (26.81 KiB) Viewed 9758 times
Remove the seal where the hand brake shaft passes through the calliper body.
- rc22.JPG (30.54 KiB) Viewed 9758 times
Clean this area up. Put a little grease on the new seal.
- rc23.JPG (28.44 KiB) Viewed 9758 times
And push firmly into place.
- rc24.JPG (27.06 KiB) Viewed 9758 times
Put some grease on the end of the worm drive like so. I don't like to put grease on any of the parts that are in contact with brake fluid so as not to contaminate the fluid.
- rc26.JPG (28.24 KiB) Viewed 9758 times
Also the little pin that goes in the end.
- rc27.JPG (22.04 KiB) Viewed 9758 times
Also grease the shaft of the hand brake lever.
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Then push the lever shaft back into the body.
- rc29.JPG (23.94 KiB) Viewed 9758 times
Then, with the pin also greased placed at the end of the worm drive, place it back within the calliper body like so. If you move the hand brake lever it will become obvious where the little pin is to be located as there is a little notch in the shaft of the hand brake lever.
- rc30.JPG (34.97 KiB) Viewed 9758 times
You will know when its in the correct place by moving the hand brake lever. This will move the worm drive in & out. Then replace the cir-clip.
- rc31.JPG (33.24 KiB) Viewed 9758 times
Rather than using brake calliper lubricant to install the other rubbers I use the same brake fluid that I use in the braking system on the car. It works really well. So put a little on your finger & wipe it around the inner seal.
- rc32.JPG (21.73 KiB) Viewed 9758 times
Also put some brake fluid on the piston & place the dust cover rubber over the piston starting from the outer end. It will locate in the groove that it is meant to sit in but just go past this until it is at the other end of the piston. You need to have the section of the rubber that is to go within the calliper sticking over from the end of the piston as shown in the picture.
- rc33.JPG (18.99 KiB) Viewed 9758 times
Now feed the rubber into the groove in which it is intended to go. Start at the bottom & work your way around. You can make sure its OK by holding the rubber with your thumb & fore-finger then give it a little twist.
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Then grease up & replace the adjuster.
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Now turn the adjuster using an Allen key. Turning anti clockwise. You will probably have to put a little pressure on the piston until it locates & starts to wind in.
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Once wound fully in, the dust rubber will locate itself into the groove. Don't forget the brake fluid on the rubber & piston. It makes the job a lot easier.
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Now put a smear of grease on the slide pin rubbers & push into place.
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- rc42.JPG (29.91 KiB) Viewed 9758 times
Now for replacing the spring to the hand brake lever. Place it over the center pillar like so with the straighter part behind the stop as shown.
- rc43.JPG (26.87 KiB) Viewed 9758 times
Now with a pair of pliers grip this section & pull it over the lever part like so.
- rc44.JPG (28.23 KiB) Viewed 9758 times
Put a little grease on the thread of the bleed screw & replace that.
- rc45.JPG (22.97 KiB) Viewed 9758 times
- rc46.JPG (24.27 KiB) Viewed 9758 times
There you go. One refurbished calliper.
