(19) Remove threaded plug from banjo bolt hole in
inboard half of caliper (Fig. 21).
(20) Install C-clamp over outboard caliper piston
nearest to bleeder screw as follows:
(a) Lay shop towel over outside of outboard cali-
per half to protect finish (Fig. 26).
(b) Place Installer, Special Tool 6454, over piston
and boot nearest to bleeder screw and hold in
place. Either side of Installer will work.
(c) Place C-clamp over tool and cloth as shown
and tighten C-clamp (Fig. 26). DO NOT USE
EXCESSIVE FORCE; excessive force could damage
caliper or piston.
(21) Place an appropriate size block of wood inside
center area of caliper, in front of piston nearest
transfer tube port. Block of wood should be large
enough to allow piston to exit piston bore just far
enough for piston to be pulled out remaining distance
by hand, but not exit the bore completely.
WARNING: DO NOT PLACE FACE OR HANDS NEAR
PISTONS OR INTO CENTER AREA OF CALIPER
WHEN USING COMPRESSED AIR TO REMOVE PIS-
TONS FROM BORE OF CALIPER. PERSONAL
INJURY CAN RESULT FROM SUCH ACTION.
WARNING: UNDER NO CONDITIONS SHOULD HIGH
PRESSURE AIR BE USED TO REMOVE PISTON
FROM CALIPER BORE. PERSONAL INJURY CAN
REULT FROM SUCH ACTION.
(22) Using a rubber tipped air nozzle, apply short
bursts of low pressure compressed air to caliper
transfer port to force piston from bore.
(23) Remove block of wood from center area of cal-
iper.
(24) Remove piston from caliper bore, but leave
piston dust boot in place.
(25) Transfer C-clamp and Installer to cover piston
boot and bore where piston was just removed (Fig.
27). It may be necessary to place a small piece of
rubber over hole in center of Installer to seal off
installer.
Fig. 24 Removing Piston Dust Boot
1 - DUST BOOTS
2 - RETAINING GROOVE
Fig. 25 Removing Piston Seal
1 - PISTON SEAL
2 - TRIM STICK
Fig. 26 Clamp Installed Over Outboard Piston
Nearest Bleeder Screw
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - SHOP TOWEL
4 - INSTALLER 6454
5 - TRANSFER TUBE PORT
ZB BRAKES - BASE 5 - 19
DISC BRAKE CALIPER - FRONT (Continued)
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