1. Teknik Kendaraan Ringan
DISC BRAKE OVERHAUL
Teknik Kendaraan Ringan
Semester 4 th Class XI
Kompetensi Kejuruan
SK-KD 12TH

2. DIAGRAM ALUR PENCAPAIAN KOMPETENSI

3. 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.

4. Componens disc brake

6. Jack up car and place safety stands in an appropriate place Remove wheel

7. remove wheel check wheel studs and lug nuts(replace if necessary)

8. remove caliber and brake pads check rotor for run out

9. Rotor for Thickness variations
PROCEDURES
if rotor needs to be turned, look up proper procedures on how to remove before removing

10. Inspect brake lines and hoses
If car has very many miles or if seal looks bad or piston rusted, replace the caliber assembly

11. Replace with a loaded caliper (ones with brake shoes in) Another option is to rebuild the caliber
to rebuild caliber

12. 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

13. 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
Hone the cylinder if piston is pitted and scored and cannot be cleaned up with crocus cloth replace the piston

14. 4. Clean up caliber with wire brush, if time permits dry and glass bead.
5. Install rubber parts lube up with brake fluid

15. 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

16. 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.

17. Clean with wire brush lightly grease all contact points between caliper and anchor plate

18. Check all rubber guide pin bushings and o-rings check the anti rattle clips replace if worn or damaged
reassembled bleed brakes

19. 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.

20. The End