Dorman D352783 Rear Disc Brake Caliper Repair Kit

1. Product Overview

The Dorman D352783 Rear Disc Brake Caliper Repair Kit is engineered to provide a direct replacement for the original components necessary to repair and restore the proper operation of disc brakes on specified vehicles. This kit is manufactured using quality components to ensure reliable performance and a long service life, offering an ideal solution for repairing failed or damaged original parts.

Key features include:

• Direct Replacement: Designed to match original components for seamless repair.
• Ideal Solution: A reliable alternative to replacing the entire caliper.
• Durable Construction: Made from high-quality materials for extended service life.
• Trustworthy Quality: Backed by Dorman's century of automotive experience.

2. Components Included

This repair kit typically includes the essential seals and components required for rebuilding a single disc brake caliper. The exact contents may vary slightly, but generally include:

• Piston Seal (Inner Seal)
• Dust Boot (Outer Seal)
• Retaining Ring/Clip for Dust Boot

Image: The Dorman D352783 Rear Disc Brake Caliper Repair Kit showing the piston seal, dust boot, and retaining ring.

3. Vehicle Compatibility

This repair kit is compatible with a wide range of vehicles. To ensure precise fitment for your vehicle, it is crucial to verify compatibility using the manufacturer's fitment tool or by cross-referencing the OEM part numbers. Below is a list of some compatible models:

• Acura: CL (2001-2003), Legend (1987-1995), RDX (2007-2013), RL (1996-2004), TL (1995-2008), Vigor (1992-1994)
• Honda: Accord Crosstour (2010-2011), Accord (1991-1997), Crosstour (2012-2013), CR-V (2002-2011), Element (2003-2011), Odyssey (1995-1998)
• Hyundai: Santa Fe (2001-2006)
• Infiniti: J30 (1993-1997), Q45 (1990-2001)
• Isuzu: Oasis (1996-1999)
• Lexus: ES300 (2002-2003), ES330 (2004-2006), LS400 (1990-1992, 1995-1997)
• Mazda: MX-5 Miata (2006-2011)
• Toyota: Avalon (2008-2011), Camry (1995-1996, 2002-2005, 2007-2011), Highlander (2001-2005), Matrix (2009-2010), MR2 (1985-1989), RAV4 (2006-2010)
• Volkswagen: Golf (2003-2006), Passat (2003-2005), R32 (2004)
• Volvo: S40 (2000-2004), V40 (2000-2004)

4. Setup and Preparation

Before beginning any brake system work, ensure you have the necessary tools and safety equipment. This procedure requires mechanical aptitude and familiarity with automotive brake systems.

4.1 Safety Precautions

• Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Work in a well-ventilated area.
• Ensure the vehicle is securely supported on jack stands or a lift. Never rely solely on a jack.
• Disconnect the negative battery terminal if working near electrical components.
• Brake fluid is corrosive; avoid contact with skin and painted surfaces.

4.2 Required Tools and Materials

• Socket/Wrench Set
• Torque Wrench
• Brake Cleaner
• Wire Brush
• Caliper Piston Compressor Tool
• Small Flathead Screwdriver or Pick Tool
• Brake Fluid (compatible with your vehicle)
• Clean Rags
• Drain Pan for Brake Fluid

5. Installation Instructions (Caliper Rebuild)

This section outlines the general steps for rebuilding a disc brake caliper using the Dorman D352783 kit. Refer to your vehicle's specific service manual for detailed torque specifications and procedures.

5.1 Removal of Old Caliper

1. Loosen lug nuts, raise vehicle, and secure with jack stands. Remove wheel.
2. Place a drain pan under the caliper. Using a flare nut wrench, loosen the brake line fitting on the caliper.
3. Remove the caliper mounting bolts and carefully detach the caliper from the rotor.
4. Completely disconnect the brake line from the caliper. Cap the brake line to prevent excessive fluid loss and contamination.
5. Remove brake pads and any shims from the caliper.

5.2 Disassembly and Cleaning

1. Carefully remove the old dust boot and retaining ring.
2. Extract the piston from the caliper bore. This can often be done by applying compressed air to the brake line port (wear safety glasses and place a rag over the piston to catch it). Alternatively, use a piston removal tool.
3. Remove the inner piston seal from its groove inside the caliper bore using a pick tool. Be careful not to scratch the bore.
4. Thoroughly clean the caliper bore, piston, and all grooves with brake cleaner and a wire brush. Ensure all rust, corrosion, and old fluid residue are removed. The bore must be smooth and free of pitting or scoring.
5. Inspect the caliper body for cracks or damage. If damaged, the caliper should be replaced, not rebuilt.

5.3 Installation of New Components

1. Apply a thin coat of clean brake fluid or caliper assembly lubricant to the new piston seal. Carefully install the new piston seal into its groove inside the caliper bore. Ensure it is seated correctly and not twisted.
2. Apply a thin coat of clean brake fluid or caliper assembly lubricant to the piston.
3. Install the new dust boot onto the piston, ensuring the lip is correctly seated in the piston's groove.
4. Carefully insert the piston into the caliper bore, ensuring it is straight. Use a caliper piston compressor tool to slowly and evenly push the piston fully into the bore.
5. Once the piston is seated, carefully work the outer lip of the dust boot into the caliper's outer groove. This can be challenging and may require a small, blunt tool or pick to gently push the lip into place.
6. Install the new retaining ring to secure the dust boot in the caliper groove.

5.4 Reinstallation and Bleeding

1. Reinstall brake pads and shims into the caliper.
2. Mount the rebuilt caliper back onto the vehicle, securing it with the mounting bolts. Torque bolts to manufacturer specifications.
3. Reconnect the brake line to the caliper, tightening the fitting securely.
4. Bleed the brake system to remove any air introduced during the repair. Start with the caliper furthest from the master cylinder and work your way closer. Follow proper brake bleeding procedures for your vehicle.
5. Check for any leaks around the brake line fitting and caliper seals.
6. Reinstall the wheel and torque lug nuts to specifications.
7. Pump the brake pedal several times to ensure proper pedal feel before driving. Test brakes at low speed in a safe area.

6. Maintenance

Regular inspection and maintenance of your vehicle's brake system are crucial for safety and longevity. While this kit repairs the caliper, consider these general maintenance tips:

• Brake Fluid Check: Regularly check brake fluid level and condition. Replace brake fluid according to your vehicle manufacturer's recommendations (typically every 2-3 years).
• Brake Pad Inspection: Inspect brake pads for wear during tire rotations or at least annually. Replace them before they wear down to the backing plates.
• Rotor Inspection: Check brake rotors for excessive wear, warping, or scoring. Resurface or replace as needed.
• Caliper Slide Pins: Ensure caliper slide pins are clean and properly lubricated to allow the caliper to move freely.
• Hose Inspection: Inspect brake hoses for cracks, bulges, or leaks. Replace any damaged hoses immediately.

7. Troubleshooting

If you encounter issues after rebuilding your brake caliper, consider the following common problems and solutions:

If troubleshooting steps do not resolve the issue, it is recommended to consult a certified automotive technician.

8. Specifications

9. Warranty Information

Dorman Products are known for their quality and reliability. For specific warranty details regarding the Dorman D352783 Rear Disc Brake Caliper Repair Kit, please refer to the official Dorman Products website or contact their customer service directly. Warranty terms typically cover defects in materials and workmanship under normal use and service.

10. Support

For further assistance, technical support, or inquiries regarding the Dorman D352783 Rear Disc Brake Caliper Repair Kit, please utilize the following resources:

• Official Dorman Website: Visit www.dormanproducts.com for product information, technical bulletins, and contact options.
• Customer Service: Contact Dorman's customer support team for direct assistance. Refer to their website for current contact numbers and hours of operation.
• Professional Installation: If you are uncomfortable performing the installation yourself, it is highly recommended to seek assistance from a qualified automotive professional.