Brake Caliper Replacement

Brake Caliper Replacement

Removal Procedure





1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
5. Remove the tire and wheel assembly.
6. Install and hand tighten a wheel lug nut in order to retain the rotor (A4WD only).
7. Compress the front caliper piston.
^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
^ Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor.
^ Remove the C-clamp from the caliper.





8. Remove the brake hose-to-caliper bolt (1) from the caliper.
Discard the 2 copper gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
9. Plug the opening in the front brake hose (2) in order to prevent excessive brake fluid loss and contamination.
Do not pinch off the brake hose with any tools.





10. Remove the caliper mounting bolts.
11. Remove the caliper.
12. Remove the brake pads.





13. Remove the bushings.
14. Remove the sleeves (RWD only).
15. Inspect the caliper bolts for corrosion or damage. Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper.

Installation Procedure





1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent.
2. Dry the brake caliper pin bolts using non-lubricated, filtered air.
3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware.





4. Install the bushings.
5. Install the sleeves (RWD only).
6. Install the brake pads.
7. Install the caliper assembly.

Notice: Refer to Fastener Notice in Service Precautions.





8. Install the mounting bolts.
^ Tighten the bolts to 51 Nm (38 lb ft).

Important: Install NEW copper brake hose gaskets.





9. Install the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
10. Install the brake hose-to-caliper bolt to the brake caliper.
^ Tighten the bolt to 44 Nm (32 lb ft).
11. Remove the wheel lug nut securing the rotor to the hub.





12. Measure the clearance between the caliper and the steering knuckle.
Measure the clearance at each end of the caliper individually and then add the measurements together.
Specification
The total should be 0.26 - 0.60 mm (0.010 - 0.024 in).
^ If the total clearance between the caliper and the steering knuckle is less than 0.26 mm (0.010 in), file the steering knuckle equally on each side until the proper clearance is obtained.
^ If the total clearance between the caliper and the steering knuckle is more than 0.60 mm (0.024 in), inspect the brake caliper and the steering knuckle for damage and replace as needed.
13. Install the tire and wheel.
14. Lower the vehicle.
15. Fill the master cylinder to the proper level with clean brake fluid.
16. Bleed the brake system.