Brake Caliper Replacement

REMOVAL PROCEDURE





1. Remove two-thirds of the brake fluid from the brake master cylinder.
2. Raise the vehicle.
3. Support the vehicle with safety stands.
4. Remove the tire and the wheel. Refer to Wheel Removal (Excessively Tight Wheels) in Tires and Wheels.
5. Compress the front brake caliper piston using a C-clamp or pliers over the top of the front brake caliper housing and against the inboard front brake pad.
6. Remove the front brake hose from the front brake caliper. Refer to Front Brake Hose Replacement.
7. Plug the front brake line and the front brake caliper housing to prevent contamination of the brake fluid.





8. Remove the front brake caliper bolts.





9. Remove the front brake caliper from the front brake rotor.
10. Suspend the front brake caliper to the upper control arm with a wire hook.
11. Inspect the front caliper bolts for corrosion.
Replace any corroded parts.
Do not attempt to polish away any corrosion.
12. Inspect the caliper bolt bushings for nicks, cuts, or corrosion. Replace any damaged parts.


INSTALLATION PROCEDURE





1. Connect the front brake caliper to the front brake rotor ensuring that the bushings are positioned correctly.
2. Install the front brake caliper bolts and the sleeve.





3. Lubricate the front caliper bolts and sleeves with silicone paste.
- Tighten the front brake caliper bolt to 51 Nm (38 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

4. Install the front brake hose to the front brake caliper. Refer to Front Brake Hose Replacement.
5. Measure the clearance between the front brake caliper and the bracket stops.





6. 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 in) total clearance. Measure the clearances individually and add them together.
7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual Bleeding) or Hydraulic Brake System Bleeding (Pressure Bleeding).
8. Remove the tire and the wheel. Refer to Wheel Installation in Tires and Wheels.

IMPORTANT: Before moving the vehicle, fill the brake master cylinder at least 1/2 way and pump the brake pedal several times to make sure it is firm. The brake pedal must be firm before moving the vehicle. Check the fluid level in the brake master cylinder after pumping the brakes.