Brake Caliper Replacement-Front

REMOVAL PROCEDURE

CAUTION: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise and suitably support the vehicle.
3. Mark the relationship of the wheel to the hub.
4. Remove the tires and the wheel.





5. Push the piston (4) onto the caliper bore in order to provide clearance between the linings and the rotor. Complete the following steps:
5.1. Install a large C-clamp over the top of the caliper housing (3) and against the back of the outboard shoe (1).
5.2. Slowly tighten the C-clamp until the piston (4) pushes into the caliper bore enough to slide the caliper (3) off the rotor. Do not overtighten the C-clamp. Overtightening the C-clamp will deform the outboard shoe (1).

NOTICE: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

6. If you remove the caliper from the vehicle for unit repair (overhaul), then remove the brake hose bolt that attaches the inlet fitting. If only the brake pads are being replaced, do not disconnect the inlet fitting.





7. Plug the openings in the caliper housing (3) and the pipe in order to prevent brake fluid loss and contamination.
8. Remove the caliper bolts (3).





9. Remove the caliper housing (1) from the rotor and the caliper bracket (2).
10. Inspect the bolt boots for the following conditions:
- Cuts
- Tears
- Deterioration
Replace the bolt boots if damage exists.

11. Inspect the piston boot for the following conditions:
- Cuts
- Tears
- Deterioration
Replace the bolt boots in the caliper bracket if damage exists.

12. Inspect the bolt boots in the caliper bracket for the following conditions:
- Cuts
- Tears
- Deterioration
Replace the bolt boots in the caliper bracket if damage exists.

13. Inspect the caliper bolts (1) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion.

INSTALLATION PROCEDURE





1. Install the caliper housing (1) over the rotor and the caliper bracket (2). Ensure that the bushings are in place.





2. Lubricate the caliper bolts (1). Use silicone grease.
Do not lubricate the threads.





3. Lubricate the two bolt boots (5) in the caliper bracket (6). Use silicone grease.

NOTICE: Refer to Fastener Notice in Service Precautions.





4. Install the caliper bolts (1). Use a screwdriver in order to push the bolt boot over the shoulder of the caliper bolt. Ensure that the bolt boot fits securely in the groove of the pin bolt.
- Tighten the caliper bolts to 85 Nm (63 lb ft).

IMPORTANT: Replace the copper gaskets.

5. Install the brake hose bolt, if removed.
- Tighten the brake hose bolt to 54 Nm (40 lb ft).

6. Remove the wheel nuts securing the rotor to the hub.
7. Install the tires and the wheels.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid.
10. Bleed the caliper if the inlet fitting was removed.
11. Apply the brake pedal approximately three times after bleeding, to seat the brake pads against the rotor.
12. Inspect the hydraulic brake system for brake fluid leaks.