Caliper Replacement

NOTE: Install all new components included in the repair kit used to service this caliper. Lubricate rubber parts with clean brake fluid to ease assembly. Do not use lubricated compressed air on brake parts as damage to rubber components may result. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. Replace shoe and linings in axle sets only. The tightening specifications are for dry, unlubricated fasteners. Perform service operations on a clean bench, free from all mineral oil materials.

Disc Brake Caliper Assembly:

REMOVE OR DISCONNECT
1. Remove 2/3 of brake fluid from master cylinder assembly.
2. Raise vehicle and suitably support. Mark relationship of wheel to hub and bearing assembly, to insure proper wheel balance upon reassembly.
3. Tire and wheel assembly. Reinstall two wheel nuts to retain rotor to hub and bearing assembly.

Compressing Piston:

4. Push piston into 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 C-clamp until piston is pushed into the caliper bore enough to slide the caliper assembly off rotor.
5. Bolt attaching inlet fitting only when caliper is to be removed from vehicle for unit repair (overhaul). If only shoe and linings are being replaced, there is no need to disconnect inlet fitting. Plug exposed inlet fitting in caliper housing and brake hose to prevent fluid loss and contamination.

Caliper Mounting:

6. Caliper mounting bolts and sleeve assemblies.

Suspending Caliper:

7. Caliper from rotor and knuckle. Do not let caliper hang from brake hose. Damage may occur. If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut. Inspect mounting bolts and sleeve assemblies for corrosion. Bushings for cuts or nicks. If damage to either part is found, replace with new parts when installing caliper. Do not attempt to polish away corrosion.

INSTALL OR CONNECT

Lubricating Caliper Cavity:

1. Liberally coat inside diameter of bushings with silicone grease.
2. Mounting bolts and sleeve assemblies.
3. Caliper over rotor into knuckle. Tighten mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.).
4. Inlet fitting, if removed. Tighten inlet fitting to 44 Nm (32 ft. lbs.).
5. Wheel and tire, aligning previous marks.
a. Remove wheel nuts securing rotor to hub and bearing assembly.
b. Install wheel and tire assembly with retaining nuts in proper sequence.
c. Lower the vehicle.
d. Torque wheel nuts.
6. Fill master cylinder to proper level with clean brake fluid. Bleed caliper if inlet fitting was removed. Recheck fluid level. Recheck brake pedal feel.