Rear Disc Brake Caliper

Rear Disc Brake Caliper

Special tools, testers and auxiliary items required

• Resetting & Extracting Tool (T10165)

Removal

• Before proceeding, refer to => [ Safety Precautions ] Service Precautions.

- Disconnect and isolate battery negative cable from battery post.

- Using a brake pedal holding tool, depress brake pedal past its first inch of travel and hold it in this position. Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open.

- Raise and support vehicle.

- Remove wheel mounting nuts (3), then tire and wheel assembly (1).

- Manually release the automatic self-adjusting mechanism tension of the parking brake lever assembly. Refer to => [ Parking Brake Automatic Adjuster Tension Release ] Parking Brake Automatic Adjuster Tension Release.

- Collapse the cable retainer fingers (2) at the end of the cable housing (3), then pull the cable housing out of the mounting bracket (1).

- Slide the cable strand out of the mounting bracket, then pull the parking brake cable strand (1) upward and unhook it from the caliper lever (2).

- Remove the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). There are two washers that will come off with the banjo bolt. Discard the washers.

When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head.

- Remove two caliper guide pin bolts (1).

- Slide the disc brake caliper (2) from the disc brake adapter bracket and brake pads.

Installation

When installing a new brake caliper it is necessary to bleed the brakes using a special procedure which has been integrated to this installation procedure.

- Remove the outboard pad (5) from the adapter bracket.

Use care when installing the caliper (2) onto the adapter bracket to avoid damaging the guide pin boots.

- Install the disc brake caliper (2) over the inboard brake pad on the brake caliper adapter bracket and the brake rotor.

When removing or installing a caliper guide pin bolt, it is necessary to hold the guide pin stationary while turning the bolt. Hold the guide pin stationary using a wrench placed upon the pin's hex-shaped head.

- Align the caliper guide pin bolt holes with the adapter bracket. Install the upper and lower caliper guide pin bolts (1). Lightly tighten the guide pin bolts at this time.

- Install the banjo bolt (3) connecting the brake flex hose (2) to the brake caliper (1). Be sure to install a new brake hose washer on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm (18 ft. lbs.).

- If removed, install the caliper lever return spring (1) between the cable lever (2) and anchor bracket (3). Do not reconnect cable equalizer at this time.

- Access the interior of the vehicle, remove the brake pedal holder, then slowly pump the brake pedal until the rear caliper fingers touch the outboard surface of the brake rotor where the brake pad was removed. Release the pedal.

- Remove the brake caliper lower guide pin bolt.

- Swing the caliper assembly upward, pivoting off the upper guide pin, until clear of the adapter bracket.

- Reinstall the outboard pad in the adapter bracket.

- Open the caliper bleeder screw at least one full turn.

Seat the caliper piston in the bore as follows:

- Insert (T10165) into caliper.

- Insert lugs on (T10165) into notches in face of caliper piston.

Do not over tighten the screw-drive. Damage to the piston can occur.

- Thread the (T10165) until it is against the caliper piston.

- Turn (T10165), rotating the piston in a clockwise direction until fully seated (bottomed) in the bore.

- Close the bleeder screw.

Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boots.

- Return the brake caliper back down over the adapter bracket into mounted position and install the lower guide pin bolt and lightly tighten.

• While bleeding air from the brake caliper in the following steps, be sure to monitor the fluid level in the master cylinder reservoir making sure it does not go dry.

- Have a helper pump the brake pedal three or four times and hold it in the down position.

- With the pedal in the down position, open the bleeder screw at least one full turn and let out fluid and air, if any.

- Once the brake pedal has dropped, close the bleeder screw. Once the bleeder screw is closed, release the brake pedal.

- Repeat the previous three steps as necessary until all trapped air is removed.

- If necessary, bleed remaining wheel circuits as necessary using normal bleeding procedure. Refer to => [ Base Brake Bleeding ] Base Brake Bleeding.

- Pull the parking brake cable strand (1) outward from the cable housing and hook it onto the caliper lever (2).

- Push the excess cable strand back into the cable housing, then insert the cable housing (3) into the mounting bracket (1) until the retainer fingers (2) lock into place. Make sure both fingers are engaged preventing removal of the cable from the bracket.

- Reconnect the parking brake cable equalizer and reset the automatic self-adjusting mechanism tension of the parking brake lever assembly. Refer to => [ Parking Brake Automatic Adjuster Tension Reset ] Parking Brake Automatic Adjuster Tension Reset.

- Install tire and wheel assembly (1) Refer to Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.).

- Lower vehicle.

- Connect battery negative cable to battery post.

- Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake pads.