Brake Caliper Threaded Connection Thread, Servicing: Instructions

The following description is for the rear brake caliper, since space is limited there and the work procedure is slightly more extensive.

The thread repair for the front brake caliper is identical.

-- Remove the wheel.

Before pressing the brake pads back, extract the brake fluid from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

-- Press the brake pads off of the brake rotor.

-- Remove the brake caliper from the wheel bearing housing.

-- Remove the brake caliper and secure with wire so that the weight of the brake caliper does not stress or damage the brake hose.

-- Move the parking brake motors into the installation position using the : Vehicle Diagnostic Tester  .

-- Remove the brake rotor.

-- Secure the drilling template -1- with the appropriate locating bolt (M12 for the rear, or M14 for the front) -2-.

Fig 1: Drilling Template

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-- Slide the brass sleeve -A- onto the special drill bit -B- from behind in direction of -arrow 1- so that the special drill bit edges do not damage the brass sleeve.

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-- Then insert the special drill bit together with the brass sleeve into the drilling template -C- in direction of -arrow 2-.

-- Place the tensioning tool -1- on the special drill bit -2- and tighten.

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The special drill bit from the tool kit has the appropriate length (including the template) for the correct hole depth.

-- Drill deep enough by hand until the tensioning tool -1- makes contact at the brass sleeve -3- in direction of -A arrows-.

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-- Loosen the locating bolt -2- slightly and then pivot the drilling template -1- to the side.

Fig 2: Drilling Template

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-- Insert the seat miller -2- into the tensioning tool -1- and lower the hole up to the stop depth of the seat miller (refer to the following illustration N46-10330).

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Stop Depth -A- on the Seat Miller

Fig 3: Stop Depth -A- on the Seat Miller

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-- To check the depression depth, insert the inverted thread insert -1-, that is with the seat -A- being inserted first into the depression.

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The thread insert seat must completely disappear into the depression.

-- Remove any shavings and wear protective eyewear.

-- Pivot the drilling template -1- back over the hole and secure with the locating bolt -2-.

Fig 4: Drilling Template

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-- Now slide the appropriate brass sleeve -D- onto the tap -E- from behind -arrow 1- so that the tap edges do not damage the brass sleeve.

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-- Put some cutting oil on the tap.

-- Insert the tap together with the brass sleeve into the drilling template -C- in direction of -arrow 2-.

Initially the brass sleeve sticks out slightly from the drilling template, however the guide can still be used.

-- Place the tensioning tool -1- on the tap -2- and tighten.

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-- Tap deep enough until the tensioning tool -1- makes contact at the brass sleeve -3- in direction of -A arrows-.

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-- Clean the hole, remove any shavings and cutting oil and wear protective eyewear.

-- Turn the thread insert -1- onto the insertion tool -2- by hand until slight resistance is felt.

The thread insert must not be turned completely onto the insertion tool, otherwise the thread insert would be prematurely deformed.

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-- Install the thread insert -1- by hand using the insertion tool -2- until it is flush with the wheel bearing housing -A- surface.

While doing so, the insertion tool -2- must not be inserted any further into the thread insert -1- before the thread insert -1- is flush with the wheel bearing housing -A-.

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-- Tension the tensioning tool on the insertion tool -2- and now turn the insertion tool through the thread insert -1-.

The installation resistance becomes noticeably greater.

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At the same time, the threads of the thread insert -1- are pressed into the wheel bearing housing -A-.

The thread repair is completed when the insertion tool -2- can be easily turned through the thread insert -1-.

-- Install the brake rotor, brake caliper and wheel.