5.29
Final Drive/Brake System
5
8. Remove the two small and two large o-rings from the
inside of mounting ears on caliper. Discard the o-
rings. Do not damage the shaft bores when removing
o-rings.
9. Thoroughly clean the bracket pins and pin bores with
br
ake cleaner.
10. To remove piston, insert a rubber-tipped air nozzle
in
to the brake hose inlet port and apply compressed
air to push out the piston.
11. Using a plastic or wood pick, remove both piston seals
fro
m the piston bore. Discard both seals.
12. Clean the caliper bore and piston with denatured
al
cohol and dry with either compressed air or a lint-
free rag.
13. Inspect the piston and piston bore for pitting, heavy
scorin
g or corrosion. Replace parts if damaged.
14. To assemble the caliper, lubricate two new piston
se
als with new brake fluid. Install each seal by
inserting one point of the seal into the bore groove,
and then work the seal around the groove with your
index finger. Do not twist, or rip the seals.
15. Coat the piston thoroughly with new brake fluid.
Evenly insert pis
ton into the bore, working it in by hand
carefully and slowly. Push piston down until bottomed
out.
16. Install two new small and two new large o-rings into
th
e caliper for the bracket pins.
17. Apply a liberal amount of silicone-based greas
e to the
bracket pins and pin bores. Install the bracket into the
caliper.
18. Inspect both brake pads prior to installation. If they are
within
the pad wear specification, reinstall into caliper.
Install two new anti-rattle springs.
19. Install the brake hose using the same routing and
o
rientation noted during removal. Torque fitting to
specification.
20. Reinstall brake caliper assembly on chain case.
T
orque fasteners to specification.
21. Fill and bleed the brake system of air. See “Brake
Fluid Replacement & Bleeding” on page 5.22.
22. Test brake system prior to returning vehicle to service.
TO AVOID POSSIBLE INJURY, DO NOT PLACE
FINGERS BETWEEN PISTON AND CALIPER TO
ATTEMPT TO CATCH IT WHEN APPLYING
COMPRESSED AIR.
WEAR EYE PROTECTION WHEN APPLYING
COMPRESSED AIR TO CALIPER.
Caliper Banjo Bolt: 240-264 in-lbs (27-30 Nm)
Brake Caliper Mounting Fasteners:
20-22 ft-lbs (27-30 Nm)
18 ft-lbs (25 Nm) QuickDrive™ Backer Plate
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