Brake Caliper Replacement
REMOVAL PROCEDURE1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise the vehicle and suitably support.
3. Mark the relationship of the wheel to the axle flange.
4. Remove the wheel and the tire.
5. Re-install two wheel nuts to retain the rotor.
6. If the caliper is to be removed for unit repair, remove the bolt attaching inlet fitting (1), and plug the opening in the caliper and/or pipe to prevent fluid loss and contamination. If only shoes and linings are being replaced, do not disconnect inlet fitting.
7. Push the piston into the caliper bore to provide clearance between linings and rotor.
^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe.
^ Slowly tighten the C-clamp until the piston is pushed into the caliper bore far enough to slide the caliper off the rotor.
8. Remove the caliper mounting bolts and sleeves.
9. Remove the caliper. If only the shoes and linings are being replaced, suspend the caliper (2) with a wire hook (1) from the strut.
10. Inspect the mounting bolts and sleeves for corrosion.
11. Inspect the bushings for cuts and nicks.
12. If damage is found use new parts when installing the caliper.
13. Do not attempt to polish away corrosion.
INSTALLATION PROCEDURE
1. Liberally coat ID of bushings with silicone grease.
2. Install the caliper.
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
3. Install the mounting bolts and sleeves.
Important: Mounting bolts and sleeves should slide through bushings with only hand pressure applied. If greater force is required, or mechanical assistance is needed, complete the following steps:
1. Remove the bolts and sleeves along the bushings.
2. Inspect the mounting bores for corrosion. If the bore shows signs of corrosion, remove the corrosion by using a 1-inch wheel cylinder honing brush.
3. Clean the bores with clean, denatured alcohol.
4. Install bushings and lubricate. Refer to Brake Caliper Overhaul.
5. Install the inlet fitting, if removed.
Tighten the mounting bolts to 51 Nm (38 ft. lbs.) fighter the Inlet fitting to 45 Nm (33 ft. lbs.).
6. Install the wheel and the tire, aligning the previous mark.
^ Remove the wheel nuts securing the rotor to the hub.
^ Lower the vehicle.
^ Torque the wheel nuts per specification.
7. Fill the master cylinder to the proper level with clean brake fluid. Bleed the caliper if the inlet fitting was removed. Recheck the fluid level.