Brake Caliper Replacement

REMOVAL PROCEDURE

CAUTION: Do not move the vehicle unto 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 the flexible hoses. Doing so can damage the hoses.

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 tire and wheel. Install two wheel nuts in order to retain the rotor.





5. Push the piston into 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 (2) over the top of the caliper housing (1) and against the back of the outboard pad (1).
5.2. Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor. Do not overtighten the C-clamp. Overtightening the C-clamp will deform the outboard pad.
6. If the caliper will be removed 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 and the brake hose in order to prevent loss and contamination of the brake fluid.





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 piston boot 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 (3) 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 (3). Use silicone grease. Do not lubricate the threads.
3. Lubricate the two bolt boots in the caliper bracket (2). 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 ft lbs).

IMPORTANT: Replace the copper gaskets.

5. Install the brake hose bolt, if removed.
- Tighten the brake hose bolt to 54 Nm (40 ft lbs).
6. Remove the wheel nuts securing the rotor to the hub.
7. Install the tire and wheels. Align the previous marks on the wheel and the hub.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid.
10. Bleed the caliper. Refer to "Hydraulic Brake System Bleeding" in Brake Bleeding.
11. Inspect the hydraulic brake system for brake fluid leaks.