Front

FRONT DISC BRAKE CALIPER

REMOVAL





1. Raise and support the vehicle.
2. Remove the front wheel and tire assembly.
3. Drain a small amount of fluid from the master cylinder brake reservoir with a clean suction gun.
4. Disconnect the brake pad wear indicator harness connector.





5. Remove brake pad wear indicator (1) from caliper (2) by removing the retaining bolt.
6. Bottom the caliper piston into the caliper by prying the caliper over.





7. Remove the caliper support spring (2) by prying the spring out of the caliper (1).





8. Remove the caliper slide pin caps (3) and slide pins (2) from the caliper (1).





9. Remove the caliper (1) from the mounting bracket (2).





CAUTION: DO NOT spill the brake fluid on any painted surfaces. Brake fluid can damage paint.

10. Remove the brake hose (4) from the caliper (3).





11. Remove the inboard and outboard brake pads (2 and 3) from the caliper (1).
12. Disassemble the caliper to clean and inspect for wear and damage.

INSTALLATION





1. Install the inboard and outboard brake pads (2 and 3) onto the caliper (1).





2. Lubricate the slide pins (2) and slide pin bushings with silicone grease.





3. Install the caliper (1) on the mounting bracket (2).





4. Install the caliper slide pins (2). Tighten the slide pins to 25 Nm (18 ft. lbs.).
5. Install the caliper slide pin caps (3).





6. Install the brake pad wear indicator (2) onto the caliper. Tighten the bolt to 8 Nm (6 ft. lbs.).





7. Connect the brake wear indicator to the brake pad.





8. Install one end of the caliper support spring (2) in the top end of the caliper and under the mounting bracket (1).
9. Install the other end into the lower caliper hole (3).
10. Hold the spring (2) into the caliper hole (3) with your thumb while prying the end of the spring (2) out and down under the mounting bracket with a screwdriver.





CAUTION: Verify brake hose is not twisted or kinked before tightening the fitting.

11. Connect the brake hose (4) to the caliper (3).
12. Fill and bleed brake system.
13. Install the wheel and tire assembly.

WARNING: DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS ACHIEVED.

14. Lower the vehicle.
15. Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved.
16. Top off the brake fluid reservoir with new fluid if necessary, and check for leaks.