Caliper Removal and Installation
RemovalWARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled.
Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators.
Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area.
1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings.
Loosen the wheel nuts.
1. Remove the center cap.
2. With the weight of the vehicle on the wheels, loosen the wheel nuts.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
3. Remove the wheel and tire assembly.
4. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets.
Inspect the pads for wear or contamination.
5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
Disconnect the front brake hose (2078).
1. Remove the front brake hose bolt.
2. Disconnect the front brake hose.
3. Remove the copper washers. Plug the front brake hose.
6. Remove the disc brake caliper.
1. Remove the two caliper bolts using a T45 Torx(R).
2. Lift the disc brake caliper off the front disc brake caliper anchor plate.
7. On 4x2 vehicles, measure the brake disc thickness.
^ Install a new brake disc and hub if not within specification.
8. On 4x4 vehicles, measure the brake disc thickness.
^ Install anew brake disc if not within specification.
9. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. Install the disc brake caliper.
1. Install the disc brake caliper.
2. Install the front disc brake caliper bolts.
2. Install the front brake hose.
^ Use new copper washers to connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the front disc brake caliper.
4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting surface.
5. Install the tire and wheel assembly.
6. Install the center cap.
7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch.
Check the brake operation.