Unscrewing the metal brake line (brake line key)


It is advisable to place something underneath the brake fluid to catch it...


With a 14 "nut from the back side open both screws with a short extension (one at the top, one at the bottom).
Make sure that the brake calliper does not fall to the ground.


So the complete brake caliper is then on the workbench...


First carefully turn the "heads" with a combination pliers until you see the locking pin at 1 and 2, then pull out the locking pin on each side (opposite the direction of the arrow).
2. left of Pos. 3 and to the right of pos. 4 is usually still a small 10mm screw, here on the picture I have already unscrewed it.
3rd pos. 3 and Pos. 4 pull out upwards (arrows up)

WARNING: At the place where the metal brake line was previously connected, FULLY blown out the piston with very little pressure, ATTENTION, danger of injury due to the ejecting brake piston.


This drawing is from the workshop manual, as we are working on a car at least 30 years old, we assume that a maximum of 1 brake piston really "shoots" out of it and the other one stays firmly in it. Simply because you don't disassemble the brake because you like it, but because the brake hangs / grinds or clamps?
The second. Brake piston which is possibly still stuck with you with a wooden rod the 2. Carefully knock out the piston.

brake pistons

This is what faulty brake pistons look like:


Here's the same picture marked with the errors again:


The bad one here are the rust notches that look like small clouds and the notch on the right piston above.
These rust grooves ensure that the piston remains stuck on the seal.


When both ring seals are outside, it looks something like this.
Clean everything thoroughly, remove all rust, especially the notches where the ring seals are inside.


Then put the gasket in the front.
Grease the interior with ATE brake grease, as well as the new brake pistons.


First, as shown here, insert the outer brake piston until the outer sealing ring can be inserted from the inside.


About this far


This is where the new sealing ring belongs


Put it in and press it into the notch with a flat, not too pointed object.

Here with sealing ring, leave the outer piston in this position.


The second. Press the 2nd piston in so far that at the point where the arrow shows it is the notch/slot.
1. push piston in
2. clean the ring seal
3. push the outer sealing ring into the groove
4. push the piston from the other side back through the other piston.


Repair of the brake caliper

To repair the brake pads you will need the repair kit from Daihatsu with part number 04479-87701-000, which is also available as a replica.

Daihatsu Charade G10

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