Pic. 8.9. Rear disc brake
1 - hand brake cable; 2 - clamp bracket; 3 - brake pads; 4 brake clamp; 5 - check; 6 - hub cover; 7 - crown protection; 8 - hub trunnion nut; 9 - washer; 10 - bearing; 11 - brake disc; 12 - casing of the seal; 13 - casing of the brake disc; 14 - hub axis; 15 - rear axle beam.
1. Block the front wheels with wedges. Loosen the bolts holding the wheels. Raise the rear of the car, put it on stands and remove the two rear wheels.
2. Clean the area around the bleeder and the attachment of the flexible conduit to the clamp. Unscrew the flexible pipe from the clamp by half a turn and tighten it slightly back. Remove the rubber cap from the air extractor. Pour the penetrating agent into the air extractor so that it gets inside the air extractor opening.
Attention: The operations described in paragraph 10.2 should not be carried out if the clamp is not disconnected from the brake pipe during the following steps.
3. Disconnect the handbrake cable 1 from the clip (pic. 8.9).
4. Loosen and remove the top bolt. If only inspection or replacement of the brake pads is performed, it is enough to tilt the clip forward, paying attention to its position on the lower bolt. Before removing the pads 3, it is necessary to mark their position so that after inspection and cleaning they will be installed exactly in their place, on the same side of the disc. After removing the pads, clean both the running surfaces of the pads and the clamp bracket 2. For notes on mounting new pads and clamp, go to 10.17
5. Unscrew and remove the lower fixing bolt 3 and remove the clip 5 (fig 8.10)
Attention: Both bolts must be replaced with new ones during assembly.
6. Clamp the pipeline more elastically with a small wrench like "Frenchman" with blunt edges so that brake fluid does not leak out after the clamp is unscrewed from the brake pipeline.
7. Place a flat liquid tank under the clamp, unscrew the clamp from the pipeline. Plug the flexible pipe seat in the clamp and clean it thoroughly.
8. Secure the clamp in a vice and unscrew the bleeder 2 with a strong hexagon socket wrench. You can also hit the air vent from above with a hammer.
9. After unscrewing the air extractor, it is necessary to remove the rubber casing 9 of the piston 8, lifting it with a screwdriver (pic. 8.10).
Pic. 8.10. Rear brake clamp
1 - bolt securing the clamp bracket to the suspension beam; 2 - air remover; 3 - fixing bolt; 4 - bolt casing; 5 - rear brake clamp; 8 - clamp bracket; 7 - piston sealing ring; 8 - piston; 9 - piston casing.
10. Using a hex socket wrench, unscrew the piston from the rear clamp (pic. 8.11).
Pic. 8.11. Reversing the piston of the rear clamp
11. Remove the gasket from the groove in the cylinder with a small screwdriver (photo 8.17)
12. Rinse the surfaces of the piston and cylinder with alcohol and check their condition. If traces of corrosion or abrasions are small, they can be sanded with sandpaper with a grit of 500 or 600. We grind the piston along the perimeter, and not along scratches along which liquid could leak under the gasket. If the surfaces are severely damaged, the piston or clamp must be replaced.
13. If the elements are in good condition, it is enough to replace the gasket 7 and the rubber casing 9. Before installing the gasket 7 of the piston 8., it is necessary to lower it into the brake fluid so that it evenly lies in the groove and is not damaged during the installation of the piston.
14. Put on the rubber casing on the piston, turn it outward and cover the surface of the piston with a thin layer of silicone grease. Then carefully screw it into the hole of the cylinder until it stops. Install the rubber casing 9 in the clamp socket.
15. Screw the air bleeder onto the silicone grease. Before installing the clamp, it must first be filled with brake fluid so that there are no problems with bleeding. To do this, you need to fix the clamp vertically. Put a plastic tube on the air bleeder and use a syringe to fill the clamp with liquid until it flows out without bubbles from the hole connecting the clamp to the elastic conduit. Screw on the air bleeder and plug the opening of the flexible pipe.
16. Now you can install the clamp in the car. Install a new self-locking bolt in the bottom hole and install the clip. Then squeeze the flexible pipe. Remove the clamping key from the pipeline. Install the brake pads, paying attention to the markings made during disassembly.
Attention: It is important that the clamp is fixed with the piston set in such a way that there is a gap between the pads and the clamp of 1 mm.
To do this, with a new lower bolt installed, it is necessary to turn the clamp and install it on the pads. The old bolt should be screwed into the upper hole and measure the gap with a feeler gauge. If the gap is incorrect, unscrew the top bolt, deflect the clamp, adjust the position of the piston by turning it to the sides. When the piston is correctly adjusted, it will be necessary to reinstall the clamp, insert a new bolt and tighten with a torque of 40 Nm.
17. Install the handbrake cable. When replacing the pads, you must first loosen the cables at the handbrake lever, then connect the cable to the clamp lever and adjust the length of the cables.
18. Remove air from the brake system.
19. After installing the clamp, put on the wheels and lower the car.
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