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.
4. Tires and wheels. Install two wheel nuts to retain rotor.
5. Push piston onto caliper bore to provide clearance between linings and rotor.
A. Install a large C-clamp over top of caliper housing and against back of outboard shoe.
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 require replacement.
6. Brake hose bolt attaching inlet fitting only if caliper is to be removed from vehicle for unit repair (overhaul). If only brake pads are being replaced, there is no need to disconnect 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
- Bolt 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 REPAIR."
^ Bolt boots in caliper bracket for cuts, tears, or deterioration. If damaged, replace boots. Refer to "CALIPER BRACKET."
- 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 housing 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 bolt boots in caliper bracket using silicon grease.
4. Caliper bolts.
- Using a flat bladed tool, push bolt boot over shoulder of caliper bolt. Bolt boot must be securely in grove of pin bolt.
- Tighten caliper bolts to 85 Nm (63 ft. lbs.).
5. Brake hose bolt, if removed.

Important: Replace copper gaskets.

- Tighten brake hose bolt to 54 Nm (40 ft. lbs.).
6. Remove wheel nuts securing rotor to hub.
7. Tires and wheels.
- Align previous marks on wheel and hub.
8. Lower vehicle.
9. Fill master cylinder to proper level with clean brake fluid.
10. Bleed caliper if inlet fitting was removed.
11. Apply approximately 778 N (175 lbs.) of force to the brake pedal after bleeding, if necessary.

Inspect
- Hydraulic brake system for brake fluid leaks.