U.S. General 40732 User manual

DISC BRAKE CALIPER TOOL SET
ASSEMBLY AND OPERATING INSTRUCTIONS
40732
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this
product. Failure to do so can result in
serious injury.
SAVE THIS MANUAL.
Copyright©2007 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may
be reproduced in any shape or form without the express written
consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
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Specifications
ITEM DESCRIPTION
T-handle 0.277 (Dia.) inches
5-5/16 (L) inches
Lead Screw 5.3 (L) x 0.620 (Dia.) inches
Caliper Sizes 1.261, 1.417, 1.654, 1.656, 1.870, 2.000, 2.129,
2.163, and 2.500 (diameter) inches
Save This Manual
You will need the manual for the safety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep the manual and invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be fol-
lowed to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in
damp or wet locations. Don’t expose to rain. Keep work area well lighted.
Do not use electrically powered tools in the presence of flammable gases or
liquids.
3. Keep children away. Children must never be allowed in the work area. Do
not let them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry
location to inhibit rust. Always lock up tools and keep out of reach of
children.
5. Do not force tool. It will do the job better and more safely at the rate for
which it was intended. Do not use inappropriate attachments in an attempt
to exceed the tool capacity.
6. Use the right tool for the job. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain
applications for which this tool was designed. Do not modify this tool and do
not use this tool for a purpose for which it was not intended.

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7. Dress properly. Do not wear loose clothing or jewelry as they can be
caught in moving parts. Protective, electrically non-conductive clothes and
non-skid footwear are recommended when working. Wear restrictive hair
covering to contain long hair.
8. Use eye and ear protection. Always wear ANSI approved impact safety
goggles. Wear a full face shield if you are producing metal filings or wood
chips. Wear an ANSI approved dust mask or respirator when working around
metal, wood, and chemical dusts and mists.
9. Do not overreach. Keep proper footing and balance at all times. Do not
reach over or across running machines.
10. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories.
Inspect tool cords periodically and, if damaged, have them repaired by an
authorized technician. The handles must be kept clean, dry, and free from oil
and grease at all times.
11. Remove adjusting keys and wrenches. Check that keys and adjusting
wrenches are removed from the tool or machine work surface before using.
12. Stay alert. Watch what you are doing, use common sense. Do not operate
any tool when you are tired.
13. Check for damaged parts. Before using any tool, any part that appears
damaged should be carefully checked to determine that it will operate
properly and perform its intended function. Check for alignment and binding
of moving parts; any broken parts or mounting fixtures; and any other
condition that may affect proper operation. Any part that is damaged should
be properly repaired or replaced by a qualified technician.
14. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use
accessories intended for use with this tool. Approved accessories are
available from Harbor Freight Tools.
15. Do not operate tool if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
16. Maintenance. For your safety, service and maintenance should be
performed regularly by a qualified technician.

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Warning:The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that may occur.
It must be understood by the operator that common sense and caution are
factors which cannot be built into this product, but must be supplied by the
operator.
Unpacking
When unpacking, check to make sure that all the parts are included. Refer to the
Parts List and Assembly Drawing at the end of this manual. If any parts are miss-
ing or broken, please call Harbor Freight Tools at the number on the cover of this
manual.
Operation
THIS TOOL WAS DESIGNED FOR USE ON THE FOLLOWING VEHICLES:
BMW, VW, GM, AUDI, FORD, HONDA, SUBARU, MAZDA, NISSAN, MITSUBI-
SHI, TOYOTA, AND ROVER. FOR DETAILED INSTRUCTIONS ON USE OF THIS
TOOL ON YOUR VEHICLE, REFER TO THE VEHICLE MANUFACTURER’S
MAINTENANCE MANUAL.
1. Jack up the vehicle and secure in place using axle stands.
2. Remove the wheel.
3. Remove the brake caliper from the vehicle mount and slide it off the brake
rotor.
Piston
Caliper (1-9)
Thrust Bolt
Assembly (11)
Plate (10)
T-handle

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4. Remove the worn brake pads and hardware.
5. Select the correct drive adapter Caliper (1-9) to fit the piston (face) holes.
6. Place the Plate (10) over the Thrust Bolt Assembly (11) center bolt.
7. Turn the Thrust Bolt clockwise to compensate for the distance between the
piston and the Caliper body.
8. Align the Caliper pins into the piston (face) holes.
9. Using a wrench, turn the Thrust Bolt clockwise until the Caliper Plate is
secure and the tool is fixed in place.
10. Turn the Thrust Bolt T-Handle clockwise to force the piston back into its
housing.
11. Install the new brake pads and bolt the Caliper back onto the carrier.
Maintenance
1. Remove all oil and grime from Caliper components with a clean cloth.
2. Always replace Caliper components in the carrying case and store in a clean
and dry location.
Parts List
Item # Description Qty
1Caliper, 1.870" (dia.) 1
2Caliper, 2.129" (dia.) 1
3Caliper, 2.500" (dia.) 1
4Caliper, 1.261" (dia.) 1
5Caliper, 1.654" (dia.) 1
6Caliper, 1.656" (dia.) 1
7Caliper, 2.163" (dia.) 1
8Caliper, 2.000" (dia.) 1
9Caliper, 1.417" (dia.) 1
10 Plate 1
11 Thrust Bolt Assembly 1
12 Carrying Case 1
Assembly Drawing

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PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER
NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO
THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PROD-
UCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THat
ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTI-
FIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES
ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL
PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER
INSTALLATION OF REPLACEMENT PARTS THERETO.
NOTE: Some parts are listed and shown for illustration purposes only
and are not available individually as replacement parts.

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LIMITED 90 DAY WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products
meet high quality and durability standards, and warrants to the original purchaser
that this product is free from defects in materials and workmanship for the period
of 90 days from the date of purchase. This warranty does not apply to damage due
directly or indirectly, to misuse, abuse, negligence or accidents, repairs or altera-
tions outside our facilities, criminal activity, improper installation, normal wear and
tear, or to lack of maintenance. We shall in no event be liable for death, injuries to
persons or property, or for incidental, contingent, special or consequential damages
arising from the use of our product. Some states do not allow the exclusion or limi-
tation of incidental or consequential damages, so the above limitation of exclusion
may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to
us with transportation charges prepaid. Proof of purchase date and an explanation
of the complaint must accompany the merchandise. If our inspection veries the
defect, we will either repair or replace the product at our election or we may elect
to refund the purchase price if we cannot readily and quickly provide you with a
replacement. We will return repaired products at our expense, but if we determine
there is no defect, or that the defect resulted from causes not within the scope of
our warranty, then you must bear the cost of returning the product.
This warranty gives you specic legal rights and you may also have other
rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]
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