screw. Submerge the free end of the tube in a
jar containing a small quantity of brake fluid.
10 Open the bleed screw approximately half
a turn, then push the piston back into its bore,
as far as it will go, using a G-clamp, or pieces
of wood, as levers. When the piston has fully
retracted, close the bleed screw, remove the
tube and refit the dust cap.
11 To refit the pads, first place the anti-rattle
shims (where fitted) in position in the carrier
bracket and fit the heat shield to the piston.
12 Place the shims against the backs of the
pads, then fit the pads to the carrier bracket. If
working on the left-hand caliper, the pad with
the warning light lead must be fitted nearest
to the centre of the car.
13 Swing the caliper down over the pads and
secure it with a new guide pin bolt. Tighten
the bolt to the specified torque.
14 Reconnect the warning light wiring plug
(where applicable).
15 Repeat the above procedure on the
opposite front brake caliper.
16 Refit the roadwheels and lower the car to
the ground.
17 Tighten the roadwheel nuts to the
specified torque and refit the wheel trims.
18 Depress the brake pedal several times to
bring the pistons into contact with the pads
then check, and if necessary top up, the fluid
in the master cylinder reservoir.
4 Front brake caliper -
removal and refitting
3
Note: Before starting work, refer to the
warning at the beginning of Section 2
concerning the dangers of hydraulic fluid, and
to the warning at the beginning of Section 3
concerning the dangers of asbestos dust.
Note: New caliper guide pin bolts and brake
hose copper washers will be required for
refitting.
Removal
1 Apply the handbrake, remove the front
wheel trim and slacken the wheel nuts. Jack
up the front of the car and support it on axle
stands. Remove the front roadwheel.
2 If working on the left-hand caliper,
disconnect the pad wear warning light wiring
plug (where fitted) and release the wiring
harness from the support clip.
3 Using a brake hose clamp, or self-locking
wrench with protected jaws, clamp the flexible
brake hose. This will minimise fluid loss during
subsequent operations.
4 Wipe clean the area around the brake hose
connection at the caliper then unscrew the
brake hose banjo union bolt at the caliper
body, and recover the two copper washers.
Tape over the hose union and caliper orifice to
prevent dirt ingress.
5 Using a spanner, unscrew the lower guide
pin bolt while holding the guide pin with a
second spanner.
6 Unscrew the upper guide pin bolt in the
same way, then lift away the caliper, leaving
the brake pads and carrier bracket in place.
7 If the carrier bracket is to be removed, undo
the two bolts securing it to the steering
knuckle, and remove the bracket complete
with brake pads (see illustration). The pads
can be removed, if required, with reference to
Section 3.
Refitting
8 Refitting is a reversal of removal. Ensure
that new guide pin bolts are fitted and tighten
all fastenings to the specified torque. Use new
copper washers on the brake hose banjo
union, and bleed the hydraulic system as
described in Section 2.
5 Front brake caliper -
overhaul
4
1 Remove the caliper from the car as
described in the previous Section.
2 With the caliper on the bench wipe away all
traces of dust and dirt, but do not inhale it, as
it is injurious to health.
3 Remove the heat shield from the caliper
piston (see illustration).
4 Using low air pressure, such as from a tyre
foot pump, eject the piston by holding the
pump hose against the caliper fluid inlet port.
5 Remove the dust cover from the piston.
6 Using a blunt instrument such as a knitting
needle, carefully extract the piston seal from
the caliper bore.
7 Clean all the parts in methylated spirit, or
clean brake fluid, and dry with a lint-free cloth.
Inspect the piston and caliper bore for signs
of damage, scuffing or corrosion, and if these
conditions are evident, renew the caliper
assembly complete. Renew the guide pins in
the carrier bracket if they are bent or
damaged, or if their rubber boots are split or
perished.
8 If the components are in a satisfactory
condition, a repair kit consisting of new seals
and dust cover should be obtained.
9 Thoroughly lubricate the caliper bore,
piston, piston seal and dust cover with clean
brake fluid, and carefully fit the seal to the
caliper bore.
10 Position the dust cover over the innermost
end of the piston, so that the caliper bore
sealing lip protrudes beyond the base of the
piston. Using a blunt instrument, if necessary,
engage the sealing lip of the dust cover with
the groove in the caliper. Now push the piston
into the caliper bore until the other sealing lip
of the dust cover can be engaged with the
groove in the piston. Having done this, push
the piston fully into its bore. Ease the piston
out again slightly, and make sure that the dust
cover lip is correctly seating in the piston
groove.
11 Remove the guide pins from the carrier
bracket, if not already done, and smear them
with high-melting-point brake grease. Fit new
rubber boots to the guide pins if necessary,
and refit them to the carrier bracket.
12 The caliper can now be refitted as
described in the previous Section.
Braking system 9•5
5.3 Front brake caliper components
4.7 Carrier bracket-to-steering knuckle
retaining bolts (arrowed)
9
1380 Rover 800 Series Remake
1 Guide pin rubber
boot
2 Caliper body
3 Guide pin bolt
4 Guide pin
5 Piston heat shield
6 Piston
7 Dust cover
8 Piston seal
9 Bleed screw
10 Clip
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