DISC BRAKE OVERHAUL

Teknik Kendaraan Ringan

Semester 4 th Class XI
Kompetensi Kejuruan
SK-KD 12TH
DIAGRAM ALUR PENCAPAIAN KOMPETENSI
 Couple of things to think about when working on
brakes.
 1. If you do not think a part will work right replace it.
 3. Always put in new brake pads, if the hardware has
problems replace it and if the caliper or piston is
worn or pitted replace it. And last but not least
inspect the hose for wear and cracks.
Componens disc brake
Jack up car and place safety
stands in an appropriate place
Remove wheel
remove wheel
check wheel studs and
lug nuts(replace if
necessary)
remove caliber and brake
pads
check rotor for run out
 Rotor for Thickness variations

PROCEDURES

if rotor needs to be turned, look up

proper procedures on how to remove
before removing
Inspect brake lines and
hoses

If car has very many

miles or if seal looks
bad or piston rusted,
replace the caliber
assembly
Replace with a loaded caliper (ones with
brake shoes in)
Another option is to rebuild the caliber

to rebuild caliber
1. Remove bleeder screw and make sure
passage is clear this is the first step if we
have a problem we need to replace the
screw or the whole caliper.
2. Removing piston out of caliper
Ways of removing pistonout of the caliper
Hydraulic pressure, just take caliper off of
rotor, set over a pan to catch the brake fluid
and step on the brake until it comes out
 Air pressure - take caliper off and use
a air nozzle to blow it out of its bore
CAUTION
if fingers are in the way you might lose
them be careful
You can also break the piston

3. Hone the cylinder if piston is pitted and

scored and cannot be cleaned up with
crocus cloth replace the piston
4. Clean up caliber with wire brush, if time
permits dry and glass bead.
5. Install rubber parts lube up with brake
fluid
 6. press piston into
bore with C clamp or
large water pump
pliers

Before you push the piston back into the

cylinder take the cap off the master cylinder
and drain out some of the fluid
If you are just changing the pads and push the
piston back into the caliper, if you have anti-
lock brakes I recommend that you flush out
and bleed the Brake fluid before you push
the piston back in. I don’t like old fluid
going back into the anti-lock components.
If we allow the junk and debris to go back up
to the anti-lock components we can have
problems. Please advise customers to
have the brake fluid flushed to get rid of the
debris and moisture in the brake fluid.
 Clean with wire brush
lightly grease all contact points
between caliper and anchor plate
• Check all rubber guide pin bushings
and o-rings
check the anti rattle clips replace if
worn or damaged

• reassembled
bleed brakes
 Instead of rebuilding the calipers
you can get a loaded caliper (ones
with brake shoes in) by replacing a
caliper instead of doing it yourself
you get some of the liability off of
you.
The End