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Front Brake Caliper Rebuild PDF Print E-mail
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Written by 1992 Daihatsu Rocky Service Manual   
Thursday, 03 November 2005
Ignore your brakes and they will go away!
DISASSEMBLY OF CALIPER
  1. Remove the rubber boot from the caliper.
  2. Pull out the clinder slide bush.
  3. Remove the bush dust boot.
WRU90-BR144
  1. Remove the boot set ring.
    CAUTION:
    • Never reuse the removed set ring.
WRU90-BR145
  1. Insert a suitable cloth or a wooden block in front of the piston. Then, pull out the piston by applying compressed air from the brake hose connecting section.
    WARNING:
    • Since the piston jumps out strongly when applying compressed air, care must be exercised so that your fingers or the like may not be caught in.
    • Be sure to put on safety goggles when using compressed air.
WRU90-BR146
  1. Remove the piston seal from the cylinder section.
    CAUTION:
    • Never reuse the removed boot.
WRU90-BR147
INSPECTION
  1. Ensure that the mounting support exhibits no damage, such as cracks and/or wear.
WRU90-BR149
  1. Ensure that the calipers exhibits no damage, such as cracks and wear.
  2. Ensure that the caliper and inner surface of the piston exhibit no damage, such as rust and/or scratches.
WRU90-BR150
  1. Ensure that the piston exhibits no damange, such as rust and/or scratches.
WRU90-BR151
  1. Ensure that the cylinder slide bush, dust boot and rubber boot exhibit no damage, such as rust and/or scratches.
WRU90-BR152
  1. Ensure that the pad guide plates exhibit no wear and/or damage.
WRU90-BR153
ASSEMBLY OF CALIPER
  1. Wash the assembling parts and dry them with compressed air.
    WARNING:
    • Be sure to put on safety goggles when using compressed air.
WRU90-BR571
  1. Apply rubber grease to the piston seal. Install the piston seal to the cylinder.
    CAUTION:
    • Never reuse the piston seal.
    • Be very careful not to scratch the edge of the piston seal.
WRU90-BR155
  1. Apply rubber grease to the cylinder boot. Install the cylinder boot to the piston.
    CAUTION:
    • Never reuse the cylinder boot.
  2. Apply rubber grease to the piston sliding surface.
WRU90-BR156
  1. Insert the piston into the cylinder.
  2. Fit the cylinder boot into the groove at the cylinder slide. Fit the set ring into the groove of the cylinder boot.
WRU90-BR157
  1. Insert the bush dust boot into the caliper.
  2. Apply rubber grease to the cylinder slide bush. Insert the cylinder slide bush into the bush dust boot. Then, fit both edge sections of the bush dust boot into the groove sections of the cylinder slide bush.
  3. Install the rubber boot to the caliper.
WRU90-BR158
 
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An (USA) alternative brake caliper rebuild kit to the OEM Daihatsu is the Raybestos part #WK2002. This is listed in the book for 1990 and older Rocky. They did not have a # for a newer Rocky. Apparently the piston size reduced in the later rigs. Boots fit perfect but I had to reuse my old

Posted by Wade Hansen, on 11/03/2005 at 09:36
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