Removal and Installation

Removal and Installation of Brake Caliper Assembly

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WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

CAUTION:
^ While removing cylinder body, do not depress brake pedal because piston will pop out.
^ It is not necessary to remove torque member mounting bolts on torque member and brake hose except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a wire so that brake hose is not under tension.
^ Do not damage piston boot.
^ If any shim is subject to serious corrosion, replace it with a new one.
^ Always replace shim and shim covers as a set when replacing brake pads.
^ Keep rotor clean, from brake fluid.
^ Burnish the brake pads and disc rotor mutually contacting surfaces after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.

REMOVAL
1. Remove tires from vehicle with a power tool.
2. Fasten disc rotor using wheel nut.
3. Drain brake fluid gradually (from bleed valve while depressing brake pedal).





4. Remove union bolt, and then remove brake hose from caliper assembly.
5. Remove torque member mounting bolts (from torque member), and remove caliper assembly (from vehicle with a power tool).

CAUTION: Do not drop brake pad.

6. Remove disc rotor.

CAUTION: Put matching marks on both disc rotor and wheel hub when removing disc rotor.

INSTALLATION

CAUTION:
^ Refill with new brake fluid DOT 3.
^ Never reuse drained brake fluid.

1. Install disc rotor.

CAUTION: Align the matching marks of disc rotor and wheel hub, which were marked at the time of removal when reusing disc rotor.

2. Install caliper assembly to vehicle, and tighten torque member mounting bolts to the specified torque. Refer to BR-21, "Components".

CAUTION: Before installing torque member to vehicle, wipe oil and grease on washer seats on steering knuckle and mounting surface of torque member.

3. Install a projection of brake hose metal fitting by aligning with protrusions on cylinder body, and tighten union bolt to the specified torque. Refer to BR-21, "Components".

CAUTION:
^ Do not reuse copper washers for union bolts.
^ Assemble brake hose securely on caliper assembly.

4. After installing caliper assembly, refill with new brake fluid and bleed air.
5. Install tires to vehicle.