Disassembly
Note. Do not remove the caliper bracket, brake pads, gaskets, gasket covers and pad holders when disassembling and assembling the working brake cylinder.
1. Loosen the guide pin bolts and remove the cylinder body from the caliper bracket.
Attention. Do not allow pads, gaskets, gasket covers, and pad holders to fall off the caliper bracket.
2. Remove the guide pins with anthers from the caliper bracket.
3. Remove bushings from drive pins.
4. Place a block of wood as shown in the figure and apply compressed air through the mounting bolt hole to remove the piston with boot.
Attention. Do not put your fingers in front of the piston!
5. Use a suitable tool to remove the piston seal from the cylinder body.
Attention. Be careful not to damage the inner walls of the cylinder.
Check after disassembly
1. Check the cylinder bore for corrosion, wear and damage. if necessary, replace the cylinder body with a new one.
Attention. Clean the cylinder body with fresh brake fluid. Do not use mineral oils, petrol or kerosene for this purpose.
2. Check the caliper bracket for wear, damage and cracks and damage.
If necessary, replace the caliper bracket with a new one.
3. Check the piston surface for corrosion, wear and damage. If necessary, replace the piston with a new one.
Attention. The sliding surfaces of the piston are coated with metal. Do not grind the piston with sandpaper.
4. Check drive pins, drive pin bolts, and dust boots for wear, damage, and cracks. Replace relevant parts if necessary.
Assembly
1. Apply polyglycol ether grease to the piston seal (1) and install the seal in the cylinder body.
Attention. Do not reuse piston seal.
2. Apply rubber grease to the piston boot (1). close the edge of the piston (2) boot and securely insert the outer edges of the boot into the groove in the cylinder body.
3. Apply brake fluid to the piston (1). Press the piston by hand to insert it into the cylinder body. At the same time, the protrusions on the anther (2) must seat properly in the grooves on the piston.
Attention. Press the piston with a smooth change of force to prevent the piston from rubbing against the cylinder mirror.
4. Apply rubber grease to the bushings and install them on the guide pins.
5. Apply rubber grease to the guide pins and boots, then install the drive pins with boots to the caliper bracket.
6. Install the cylinder body on the caliper bracket and tighten the guide pin bolts to the specified torque.
Adjustments after installation
Lapping procedure for brakes
The running in of new brake surfaces is carried out according to the procedure described below after grinding or replacing the brake disc, pads, or in the event of a brake pedal failure at a short distance.
Attention.
- Care must be taken and the speed of the vehicle must be monitored, as non-lapped brake pads do not provide the required performance
- Perform this procedure only on safe roads with low traffic. Exercise extreme caution.
1. Drive the car onto a straight, level road.
2. Having slightly dispersed the car, press the brake pedal with force for three to five seconds until the car comes to a complete stop.
3. Drive for a few minutes without depressing the brake pedal to allow the brakes to cool.
4. Repeat steps 1 to 3 until the brake disc is completely lapped.