Front brake caliper (Discovery 1)

Removal

1. Remove the front wheels.

2. Move aside the spring protection of the brake hose.

3. Use a suitable clamp to clamp the brake hose to prevent brake fluid from leaking.

4. Disconnect the brake pipe from the hose. Plug the pipe.

5. Remove the retaining pins and brake pads. If you plan to reinstall the pads, mark the locations where they will be installed.

6. Loosen the mounting bolts and remove the caliper.

Repair

Note: Do not separate the caliper halves.

7. Wash the caliper with brake cleaner.

8. Using the LRT-70-500 clamp, insert the pistons of the inner half of the caliper into the housing. Using a wooden block and compressed air to adjust the piston release speed, push the pistons out of the outer half of the caliper.







9. Mark the piston installation locations.

10. Using a hook, remove the boot holder.

11. Carefully remove the boot and seal. Be careful not to damage the grooves in the caliper body.

12. Wash the caliper pistons and cylinders with brake cleaner. If there are any nicks or scratches on the piston or cylinder, replace the caliper.

Installing external pistons

13. Lubricate the new seal with clean brake fluid. Place the oil seal into the groove of the caliper cylinder by hand. The oil seal and its seat are not the same size: you will feel the oil seal coming out of the groove.

14. Lubricate the corresponding piston with brake fluid. Insert the piston into the caliper by hand. The piston head should protrude from the caliper by approximately 8 mm.

15. Lubricate the new dust boot with brake fluid, place the dust boot on the piston and insert it into the groove of the caliper. Using the LRT-70-500 clamp, press in the boot holder.

Internal pistons

16. The procedure for replacing the inner piston seals is similar to the replacement for the outer ones. Repeat steps 8-15.

Installation

17. Installation is carried out in reverse order. The tightening torque of the caliper mounting bolts is 82 Nm, and the wheel nuts are 130 Nm.