Honda Civic Service Manual: Rear Brake Caliper Overhaul

Avoid breathing dust particles.

Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Clean all parts in brake fluid and air dry; blow out all passages with compressed air.

Make sure no dirt or other foreign matter gets in the brake fluid.

Make sure no grease or oil gets on the brake discs or pads.

Do not reuse drained brake fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.

Refer to the Exploded View as needed during this procedure.

1.

Remove the pad spring (A).

2.

Rotate the piston (A) counterclockwise by using the locknut wrench, and remove the piston and piston boot (B).

NOTE: Be careful not to damage the piston.

3.

Remove the piston seal (A).

NOTE: Be careful not to damage the inner surface of the cylinder wall with the tool.

4.

Install the rear caliper spring compressor on the spring guide (A) inside of the caliper body.

5.

Loosen the locknuts (B) on the top of the shaft (C), and turn the shaft clockwise until the plate (D) touches the caliper body.

6.

Turn the lower locknut (A) until contacts the plate.

7.

Turn the shaft for 1/4 to 1/2 clockwise to compress the adjusting spring B.

8.

Remove the circlip (C).

9.

Turn the lower locknut until it contacts the plate again, then lock it in place with the upper locknut.

NOTE: Leave the locknuts in this position for caliper reassembly.

10.

Remove the rear caliper spring compressor.

11.

Remove the spring guide (C).

12.

Remove adjusting spring B.

13.

Remove the spacer (D).

14.

Remove bearing A.

15.

Remove the adjusting bolt (E).

16.

Remove the cup (F).

17.

Remove the sleeve piston (A).

18.

Remove the rod (B).

19.

Remove the O-ring (C).

20.

Remove the return spring (A).

21.

Remove the lever/shaft (B).

NOTE: Do not loosen the parking nut (C) with the shaft attached to the caliper. When disassembling the lever and the shaft, clamp the lever in a vice and loosen the nut.

22.

Remove the shaft cover (D).

23.

Remove the caliper pins (A).

NOTE: The upper and lower caliper pins are different. During installation, make sure the caliper pins are in the proper positions.

24.

Remove the pin boots (B).

Avoid breathing dust particles.

Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.

Clean all parts in brake fluid and air dry; blow out all passages with compressed air.

Before reassembling, check that all parts are free of dirt and other foreign particles.

Make sure no dirt or other foreign matter gets in the brake fluid.

Make sure no grease or oil gets on the brake discs or pads.

Do not reuse drained brake fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system.

Coat the piston, the piston seal groove, and the caliper bore with clean brake fluid.

Use recommended greases in the rear caliper set.

After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

Refer to the Exploded View as needed during this procedure.

NOTE: When disassembling the lever and the shaft, assemble them according to the following procedure, referring to the exploded view beforehand, then install them to the caliper.

1.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the caliper pins (A) and the new pin boots (B).

2.

Install the pin boots.

3.

Install the caliper pins.

NOTE:

4.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to a stop pin (A) of the caliper body.

NOTE: Check if notch of the stop pin faces to the cylinder.

5.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the seal of a new shaft cover (B).

6.

Install the shaft cover.

7.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the hole (C) in the shaft.

8.

Install the lever/shaft (D).

NOTE:

9.

Install the return spring (E).

10.

Install the rod (A) to the shaft (B) so that it turns toward the center.

11.

Install the new O-ring (C) to the sleeve piston (D).

12.

Install the two pins (E) of the sleeve piston into the two holes (F) of the caliper body, so that the rod is inserted in the hole in the bottom of the sleeve piston.

13.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the new cup (C), and assemble to the adjusting bolt (D).

NOTE: Install the cup with the groove facing toward bearing A.

14.

Assemble bearing A, the spacer (E), adjusting spring B, and the spring guide (F),

15.

Install them into the caliper body.

16.

Install the rear caliper spring compressor on the spring guide (A) in the caliper body.

17.

Turn the shaft (B) clockwise until the plate (C) touches the locknut (D).

18.

Check that the bottom (E) of the spring guide is lower than the circlip installation groove (F) in the caliper body.

19.

Install the circlip (A) with the snap ring pliers.

NOTE: Make sure the circlip securely fits in the groove of the caliper body.

20.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the new piston seal (A).

21.

Install the piston seal.

22.

Apply a thin coat of Honda silicone grease (P/N 08C30-B0234M) to the new piston boot (B).

23.

Install the piston boot.

24.

Apply brake fluid to the outer surface of the piston.

25.

Set the piston in place on the caliper body.

26.

Rotate the piston clockwise with the locknut wrench to install it.

NOTE:

27.

Install the pad spring (A).