Brake Caliper Replacement - Rear

REMOVAL PROCEDURE





1. Remove 2/3 of the brake fluid from the master cylinder.
2. Raise and support the vehicle.
3. Mark the relationship of the wheel to the hub and bearing.
4. Remove the tire and wheel assembly.
Reinstall 2 wheel nuts in order to retain the rotor.
5. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor. Complete the following steps:
5.1. Install a large C-clamp (3) over the top of the caliper housing (1) and against the back of the outboard pad.
5.2. Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough to slide the caliper (1) off the rotor. Do not overtighten the C-clamp.





6. Remove the bolt (3) attaching the inlet fitting.
7. Plug the openings in the caliper housing and the hose fitting in order to prevent brake fluid loss and contamination.
8. Remove the caliper bolts (1).
9. Remove the caliper housing (2) from the caliper bracket (4).
10. Inspect the piston boots for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the piston boots if damage exists.

11. Inspect the caliper bracket boots for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the caliper bracket boots if damage exists.





12. Inspect the caliper bolts (1, 3) for corrosion or damage. If corrosion is found, use new parts, including bushings, when installing the caliper. Do not attempt to polish away corrosion.

INSTALLATION PROCEDURE





1. Install the caliper (2) to the caliper bracket (12). Ensure that the bushings are properly in place.
2. Lubricate the caliper bolts (1, 3) with silicone grease. Do not lubricate the threads.
3. Lubricate the 2 rubber boots (4, 13) in the caliper bracket (12) with silicone grease.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the caliper bolts (1, 3). Ensure that the boot is securely in the groove of the caliper bolt.
^ Tighten the caliper bolts (1, 3) to 110 Nm (81 lb ft).
Important: Replace the copper gaskets (3).





5. Install the brake hose bolt (1).
^ Tighten the brake hose bolt to 50 Nm (37 lb ft).
6. Remove the wheel nuts securing the rotor to the hub.
7. Install the tire and wheel assembly.
Align the index marks on the wheel and the hub.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid.
10. Bleed the entire brake system.
11. Apply approximately 778 N (175 lbs.) of force to the brake pedal 3 times in order to seat the pads against the rotor.
12. Inspect the hydraulic brake system for brake fluid leaks.