INSTRUCTIONS FOR REPLACING THE BRAKE CALIPER

Please read and follow all instructions carefully. You’ll find the same instructions in the brake caliper pack. Remember to keep them for the entire product life cycle. Hand them over to the new owner if you sell your vehicle.

We recommend you only perform those steps required for replacing the spare part or parts desired.

All the information in this article applies to both types of calipers, unless otherwise specified.

Ogni informazione compresa in questo articolo, se non diversamente specificato, è valida per tutti i tipi di pinze.

Replacement procedure

Here is the procedure for replacing vehicle fixed calipers for the following brake calipers:

Caliper with pad retaining pins
Caliper with central pin.
Caliper with central bridge.

Disassembling the caliper:

1. Remove the wheel.

2. Mark the positions of the springs, split pins, pins, pads, wear indicator and points of attachment on the chassis and on the caliper. The marks are necessary for correct refitting of the parts.

3. Disconnect the wear indicator cable (point 1), where present, from the terminal in the vehicle, releasing it from any attachments on the chassis and on the caliper.

Depending on the type of caliper, follow the procedure set out below.

Disconnection of the wear indicator cable and removal of safety split pins

a) Caliper with pad retaining pins:

For models fitted with safety split pins (point 2), remove them using a pair of pliers.

Slide out one of the pins (point 3) using a hammer and pin driver, far enough to allow the operation to be completed by hand, then remove completely, keeping the spring (point 4) in position with one hand.

Remove the spring (point 4) and any other pins (point 5).

b) Caliper with central pin

Unscrewing and removal of the pin fastening screw

Note the position of the pin and fastening screw on the caliper to ensure correct re-assembly.

Using a pipe wrench, unscrew the fastening screw (point 6) of the pin (point 7).

Remove the fastening screw (point 6).

Slide out the pin (point 7) using a hammer and pin driver, far enough to allow the operation to be completed by hand, then remove completely, keeping the spring in position with one hand. Remove the spring.

4. Open the brake fluid reservoir cap and check the fluid level.

CAUTION! The piston pulling back steps described below cause the brake fluid level in the reservoir to rise. Make sure the level of brake fluid won’t cause a leak, as this would damage the painted parts of the vehicle.

5. Pull away the pistons slightly using a retractor or other suitable tool, pressing on the pads (point 8). The piston pulling back must subsequently allow the caliper to be loosened from the disc.

Positioning of a spacer inside the vehicle

6. Place a spacer (point 9) inside the passenger compartment between the seat and the brake pedal to make sure the pedal remains pressed for the duration of these operations.

WARNING! This allows the brake hydraulic circuit to be closed, avoiding any brake fluid from leaking.

CAUTION! During all the phases described below, make sure the brake fluid does not come into contact with parts of the vehicle which would be damaged, especially painted parts. Promptly wipe off any accidental brake fluid splashes or leaks with kitchen towel and clean with water.

Direction arrows for unscrewing the fastening screws and removing the caliper supply line

7. Loosen the supply line (point 10) on the caliper enough to be able to screw it off completely by hand, but avoid any brake fluid leaking out.

8. Unscrew the fastening screws (point 11) using an open-ended spanner and remove the caliper from the hub bracket. Detach the supply line (point 10) completely from the caliper.

9. Move the caliper away from the vehicle, resting it on a work top.

10. Promptly wipe off any brake fluid leaks.

11.Keep the supply line raised to prevent any accidental fluid leaks.

12. Remove the pads (point 8).

13. Use a marker to mark the direction of rotation of the disc on the pads to avoid reassembling them incorrectly.

Fitting the new caliper

Stainless steel shims on the back of the pads

1. Where present, correctly reposition the stainless steel shims (point 12) on the back of the pads (point 8), replacing them if necessary.
The shims are correctly positioned when the two lips (point 13) rest firmly on the upper edge of the back of the pads and the arrows stamped on them are pointing in the disc rotation direction.

2. Fit any springs in their seats.

3. Refit the pads (point 8) housing them correctly in their seats, ensuring that any arrows (point 14) stamped on them are pointing in the disc rotation direction.

4. If there are devices to be fixed to the pads, new devices (point 15) must be fitted on the pistons (point 16).

WARNING! Check the correct positioning of any springs in the pad seats.

DANGER! Pads must be inserted with the friction material facing the disc.

Depending on the type of caliper, follow the procedure set out below.

a) Caliper with pad retaining pins

Pin inserted in the caliper and in the pads

Refit one of the pins (point 5) in the dedicated seats in the caliper and in the pads, locating it using a hammer and pin driver. A pin is correctly located when it will go no farther and the hammer blow sounds stronger and metallic.

Refit the spring (point 4) observing the direction of any arrows.

Refit any other points (point 3) exerting a firm pressure on the spring with one hand, then locate it using a hammer and pin driver.

Check the spring is correctly positioned.

For models fitted with safety split pins (point 2), reposition them using a pair of pliers.

b) Caliper with central pin

Position the spring (point 17).
Insert the pin (point 7) in the dedicated seats in the caliper, exerting a firm pressure on the spring with one hand, then locate it using a hammer and pin driver.

CAUTION! Make sure the pin is correctly positioned in the seat indicated in figure U and located on the supporting surface.

Using a pipe wrench, screw in the fastening screw (point 6) without tightening it completely.

WARNING! The fastening screw is self-locking and has a greater resistance to tightening than ordinary screws.

Using a torque wrench, tighten the fastening screw (point 6) at the torque specified in the following table:

Bleeder plug	M8x1,25
Tightening torque	27÷33 Nm

Positioning the spring, inserting the pin and tightening the fastening screw

Cleaning the braking surface, disc and contact faces of the caliper on the hub bracket

5. Clean the braking surface (point 18) on the disc (point 19) and the supporting surfaces of the caliper on the hub bracket using a degreasing product (e.g. solvent SE 47).

6. Position the caliper on the hub bracket, inserting the disc (point 19) between the pads.

7. Tighten the fastening screws with an open-ended spanner, applying the tightening torque recommended by the vehicle manufacturer.

Bleeder plug connected to a container to collect the fluid

8. Alternatively, use the following recommended tightening torques for reference:

Type of screw	M12x1,25 M12x1,5 M12x1,75 M14x1,5
Tightening torque	100 Nm 115 Nm 115 Nm 165 Nm

9. Reconnect the wear indicator cable, where present, to the terminal in the vehicle and to any attachments on the chassis and on the caliper.

10. Reconnect the brake fluid supply line (point 10).

11. Remove the spacer you previously placed inside the passenger compartment, thereby releasing the pedal from the brake and allowing the circuit to reopen.

12. Remove the protective cap (point 20) and connect a transparent tube to the bleeder plug (point 21) on the caliper, the ends of which should be placed in a container to collect any fluid.

13. Open the bleeder plug (point 21).

14. Repeatedly press the vehicle brake pedal until brake fluid starts to flow out of the bleeder plug.

15. Holding down the pedal, close the bleeder plug. Release the pedal, wait a few seconds, then repeat the process until fluid without any air bubbles flows out and until the usual resistance and travel of the brake pedal are restored.

16. Tighten the bleeder plug applying the tightening torque specified in the following table:

Bleeder plug	M6x1 M8x1,25 M10x1 M12x1
Tightening torque	5÷7 Nm 7÷10 Nm 17÷20 Nm 18÷22 Nm

Removing the tube and closing the bleeder plug

17. Remove the transparent tube and reposition the protective cap on the bleeder plug.

18. Repeat the bleeding procedure for any other bleeder plugs.

19. After the bleeding process, pull back the pistons in the caliper completely using an appropriate tool (such as a retractor) and then top up the fluid level, as recommended by the manufacturer.

20. Close the brake fluid reservoir cap.

21. With the engine running, apply strong pressure to the vehicle brake pedal and check there are no fluid leaks from the caliper or abnormal pressure losses in the circuit and that the rear brake lights come on.

DANGER! If fluid is leaking from the caliper, repeat all the steps set out in this document to pinpoint the cause and remedy the problem.

22. Refit the wheel.

General and safety information

This Brembo product has been designed to comply with all applicable safety standards. Products are not intended to be used differently from the specific use for which they have been designed and manufactured. Use for any other purpose, or any modification to or tampering with the Product can affect the performance of the Product and may render the Product unsafe.

Such modification or improper use will void the Limited Warranty, and may subject the individual so using the Product to liability for bodily injury or property damage to others.

In these instructions, the “DANGER!” warning means procedures which, if not observed, have a high degree of probability that they will cause serious injury or even death. “CAUTION”” means procedures which, if not observed, could result in physical damage whereas “WARNING!” means procedures which, if not observed, could possibly cause damage to the vehicle.

DANGER!

Before commencing replacement, ascertain that the spare parts are suitable for the make and model of the vehicle. This Product is vital to the safe operation of the vehicle on which it is installed, and it is intended to be installed only by a skilled, qualified individual who has been trained and/or is experienced in the installation and use for which the Product is intended.

The installer must be equipped with the proper tools of his trade, and with the knowledge and experience to deal with vehicle repairs. Improper or incorrect installation, whether caused by a failure to follow these Instructions faithfully and completely or otherwise, will void the Limited Warranty and could subject the installer to liability in the event of personal injury or property damage.

The worn parts replaced by this Product must not be installed on any other product. This could result in property damage and personal injury, including death.

Avoid contact of grease and other lubricants with the braking surfaces of the disc and pads as this could affect the efficiency of the braking system.

Always check that the brake fluid level in the reservoir is between the minimum and maximum levels indicated on the reservoir. An incorrect level can cause brake fluid leaks or reduced braking system efficiency. Too much or too little brake fluid in the reservoir could cause the brakes not to perform properly resulting in personal injury, including death.

Brembo shall not be liable for any damage or injury caused to or by any person operating a vehicle on which a replacement product has been improperly installed.

CAUTION!

Replaced parts must be disposed of in accordance with the law.

It is vital to avoid sharply striking and/or damaging the Product, its parts and its components, as this can impair their efficiency and may cause them to malfunction. If necessary, replace any damaged part or component. To avoid injury we recommend the following:

Use suitable equipment to prevent the inhalation of dust raised during cleaning of the parts.
Always wear gloves during disassembly and assembly of components with sharp edges.
Do not allow skin surface to make direct contact with the friction material of pads and brake shoes since this could cause abrasions.
Do not introduce your hands in the seat of the pads when removing the caliper pistons using compressed air as this involves the risk of crushing your hands.
Avoid direct contact with the brake fluid as it can cause irritation to the skin and eyes. In the event of accidental contact, clean thoroughly in accordance with the vehicle or brake fluid manufacturer’s instructions.
Do not subject the electrical components to electrostatic charges or to impact which could damage the plastic parts.
Protect the disassembled electrical components from humidity.
Ensure correct connection of any electrical contacts, checking that the warning lights come on. If they do not, non-operation of the warning lights can cause a reduction in efficiency of the braking system, or brake signalling failure.

WARNING!

Do not use sharp tools to fit rubber components as this could damage them. Make sure any damaged parts are replaced.

Warranty limitations

This warranty covers all the conformity defects occurring within two years from delivery of the good. The consumer is required to report to the seller the conformity defect within two months from the date of discovery of the said defect, without prejudice to the fact that the limitations period for taking action aimed at seeking redress for the defect is twenty-six months from delivery of the good. In the event of a conformity defect, the user has the right to repair or replacement of the good, or to an appropriate price reduction or termination of the contract, as established by art. 130 of the Consumer Code, where applicable.

This warranty constitutes the only warranty provided in relation to this product and replaces any other warranties, both verbal and written.

INSTRUCTIONS FOR REPLACING THE BRAKE CALIPER

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