Brake Caliper Removal and Installation

REMOVAL AND INSTALLATION

Brake Caliper

Material:

Material

Removal

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

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. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the front brake flexible hose flow bolt and discard the 2 copper washers.

3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots.

NOTE: Do not allow the brake caliper to hang from the brake flexible hose. Use a suitable tool to support the brake caliper.

Remove the 2 brake caliper bolts and the brake caliper.
4. Inspect the brake caliper for defects.
^ If leaks or damaged boots are found, install a new brake caliper.

Installation

1. CAUTION: Tighten the bottom locator pin caliper bolt before tightening the top guide pin caliper bolt.

Position the brake caliper and install the 2 bolts.
^ Tighten to 44 Nm (32 ft. lbs.).
2. Using 2 new copper washers, position the brake flexible hose and install the brake caliper flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
3. Bleed the brake caliper.
4. est the brake system for normal operation.