15A long thin pair of circlip pliers will now be
required to release the key plate retaining
circlip from the caliper bore (see illustration).
With the circlip removed, the pushrod and key
plate can be pulled out.
16Remove the handbrake strut from the
caliper bore.
17Remove the handbrake lever return spring
and stop bolt. Pull the lever and shaft nut out
of the caliper. Prise out the shaft seal (see
illustration).
18Clean the handbrake shaft using wire
wool; renew the shaft if it is badly corroded.
The shaft bush in the caliper can also be
renewed if necessary. Pull out the old bush
with an internal puller or slide hammer, and
press in the new bush to 7.5 mm (0.30 in)
below the shaft seal lip (see illustration). The
slot in the side of the bush must line up with
the pushrod bore in the caliper.19Having renewed components as
necessary, commence reassembly by
smearing a little brake grease or anti-seize
compound on the handbrake shaft and bush.
20Fit a new handbrake shaft seal to the
caliper. Pass the shaft through the seal and
into the caliper, taking care not to damage the
seal lips.
21Refit the handbrake lever stop bolt and
return spring.
22Refit the handbrake strut, lubricating it
with brake grease.
23Fit a new O-ring to the base of the
pushrod. Refit the pushrod and the key plate,
engaging the pip on the key plate with the
recess in the caliper. Secure the key plate
with the circlip.
24Refit the washer, spring and spring cover.
Compress the spring and refit the circlip, then
release the spring compressor.
25Lubricate the caliper bore with clean
hydraulic fluid and fit a new piston seal.
26Reassemble the piston components.
Lubricate the contact face of the adjuster nut
with a little brake grease, then fit the adjuster
nut (with new seal), thrust bearing,
thrustwasher, wave washer and the second
thrustwasher. Secure with the circlip.
27Fit a new dust-excluding seal to the
grooves in the piston and caliper bore as the
piston is refitted (see illustration). Screw the
piston into the caliper bore with the tool used
during removal.
28Renew the guide pin gaiters and apply a
little brake grease or anti-seize compound to
the guide pins when refitting the caliper to its
carrier bracket.
Refitting
29Refitting is a reversal of removal, but on
completion bleed the rear brake circuit and
check the operation of the handbrake.
Note: From 1987, thicker brake discs were
fitted. If the later discs are fitted to earlier
models, longer wheel studs must be fitted to
accommodate the increased thickness.
Consult a dealer for further advice.
Front disc
1Apply the handbrake, loosen the relevant
roadwheel nuts, then jack up the front of the
vehicle and support on axle stands (see
“Jacking and Vehicle Support”). Remove the
roadwheel.
2Remove the disc caliper and carrier bracket
but do not disconnect the flexible hose.
Support the caliper on an axle stand to avoid
straining the flexible hose.
3Rotate the disc and examine it for deep
scoring or grooving. Light scoring is normal,
but if excessive, the disc should be removed
and either renewed or reground by a suitable
specialist. Scrape any corrosion from the disc.
4Using a dial gauge or a flat metal block and
feeler blades, check that the disc run-out
does not exceed the limit given in the
8Brake disc - examination,
removal and refitting
Braking system 10•11
10
7.14d . . . and the washer
7.27 Dust-excluding seal fitted to piston
and caliper bore7.18 Handbrake shaft bush correctly fitted
X = 7.5 mm (0.30 in)7.17 Handbrake shaft and associated
components
7.15 Remove the circlip (ends arrowed) to
release the pushrod and key plate
7.14c . . . the spring itself . . .7.14b . . . then the spring cover . . .
Caution: Refer to the
precautions in Section 1.
