Brake Caliper Replacement

Brake Caliper Replacement

Removal Procedure

1. Inspect the fluid level in the brake master cylinder.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
5. Remove the tire and the wheel assembly.





6. Compress the front caliper piston.
6.1. Install a large C-clamp (3) over the top of the caliper housing (2) and against the back of the outboard pad.
6.2. Slowly tighten the C-clamp (3) until the piston pushes into the caliper bore enough to slide the caliper off the rotor.
6.3. Remove the C-clamp (3) from the caliper.





7. Remove the front brake hose from the front brake caliper.
8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
9. Plug the opening in the front brake hose in order to prevent excessive brake fluid loss and contamination. Do not pinch off the brake hose with any tools.
10. Remove the front brake caliper bolts.
11. Remove the front brake caliper from the front brake rotor.
12. Remove the front brake caliper from the vehicle.
13. Remove the brake pads from the rotor.
14. Inspect the front caliper bolts for corrosion. Replace any corroded parts. Do not attempt to polish away any corrosion.
15. Inspect the caliper bolt bushings for nicks, cuts, or corrosion. Replace any damaged parts.

Installation Procedure





1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent.
2. Dry the brake caliper pin bolts using non-lubricated, filtered air.
3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware.
4. Install the front brake pads.
5. Connect the front brake caliper to the brake caliper bracket ensuring that the bushings are positioned correctly.
6. Install the front brake caliper bolts and the sleeves.

Notice: Refer to Fastener Notice in Service Precautions.





7. Lubricate the front caliper bolts and sleeves with high temperature silicone brake lubricant.
Tighten the front brake caliper bolts to 51 Nm (38 lb ft).
8. Remove the rubber cap or plug from the exposed brake pipe fitting end.
9. Install the front brake hose to the front brake caliper.

Important: Install NEW copper brake hose gaskets.

10. Assemble the NEW copper brake hose gaskets, and the brake hose bolt to the brake hose.
11. Install the brake hose to caliper bolt and NEW washers to the brake caliper.
Tighten the brake hose to caliper bolt to 50 Nm (37 lb ft).





12. Measure the clearance between the front brake caliper and the bracket stops.
13. If necessary, remove the front brake caliper and file the ends of the bracket to obtain a 0.26 to 0.60 mm (0.010 to 0.024 inch) total clearance. Measure the clearances individually and add them together.
14. Install the tire and the wheel assembly.
15. Lower the vehicle. Refer to Vehicle Lifting.
16. Fill the master cylinder to the proper level with clean brake fluid.
17. Bleed the hydraulic brake system.
18. Inspect the hydraulic brake system for brake fluid leaks.