Caliper

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.

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

REMOVE OR DISCONNECT
1. Two-thirds of the brake fluid from master cylinder.
2. Raise vehicle and suitably support.
3. Mark relationship of wheel to hub and bearing.
4. Tire and wheel.
- Install two wheel nuts to retain rotor.
5. Push piston onto caliper bore to provide clearance between pads and rotor.
A. Install a large C-clamp over top of caliper housing and against back of outboard pad.
B. Slowly tighten C-clamp until piston is pushed into the caliper bore enough to slide the caliper off rotor.
- If C-clamp is tightened too far, the outboard shoe will be deformed and will require replacement.
6. Brake hose bolt attaching inlet fitting.
- Plug openings in caliper housing and pipe to prevent brake fluid loss and contamination.
7. Caliper bolts.
8. Caliper housing from rotor and caliper bracket.

Inspect
- Caliper bracket boots for cuts, tears or deterioration.
^ Replace if damaged. Refer to "CALIPER BRACKET."
- Piston boot for cuts, tears, or deterioration. If damaged, replace boots. Refer to "CALIPER UNIT REPAIR."
- Caliper bolts for corrosion or damage.
^ If corrosion is found, use new parts including bushings when installing caliper.
^ Do not attempt to polish away corrosion.

INSTALL OR CONNECT

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. the manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

1. Caliper over rotor and caliper bracket.
- Make sure bushings are in place.
2. Lubricate caliper bolts using silicone grease.
- Do not lubricate threads.
3. Lubricate two rubber boots in caliper bracket using silicone grease.
4. Caliper bolts.
- Using a flat bladed tool push boot over shoulder of caliper bolt. Boot must be securely in groove of caliper bolt.
- Tighten caliper Bolts to 43 Nm (32 ft. lbs.).
5. Brake hose bolt.

Important: Replace copper gaskets.

- Tighten brake hose bolt to 44 Nm (32 ft. lbs.).
6. Remove wheel nuts securing rotor to hub and bearing.
7. Tires and wheels.
- Align previous marks on wheel and hub and bearing.
8. Lower vehicle.
9. Fill master cylinder to proper level with clean brake fluid.
10. Bleed the entire brake system.