Brake Caliper Replacement

Brake Caliper Replacement

Removal Procedure





1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Mark the relationship of the wheel to the hub and bearing assembly in order to ensure proper wheel balance upon reassembly.
5. Remove the tire and wheel assembly. Reinstall 2 wheel nuts in order to retain the rotor to hub and bearing assembly.
6. 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 enough in order to slide the caliper assembly off the rotor.





7. Remove the bolt that attaches the inlet fitting (5). Plug the exposed inlet fitting (5) in the caliper housing and the brake hose in order to prevent fluid loss and contamination.
8. Remove the caliper mounting bolts (1) and sleeve assemblies.





9. Remove the caliper from the rotor and knuckle.

Important: Do not attempt to polish away corrosion.





10. Inspect the mounting bolts (1) and sleeve (4) assemblies for corrosion.
11. Inspect the bushings (2) for cuts and nicks.
12. If damage to either part is found, replace with new parts when you install the caliper.

Installation Procedure





1. Liberally coat the inside of the diameter of the bushings (4) with silicone grease (4).
2. Install the mounting bolts (1) and the sleeve (4) assemblies.

Notice: Refer to Fastener Notice in Service Precautions.





3. Install the caliper (2) over the rotor into the knuckle.
Tighten
Tighten the mounting bolt and sleeve assemblies to 51 Nm (38 lb ft).





4. Install the inlet fitting (5).
Tighten
Tighten the inlet fitting to 44 Nm (32 lb ft).
5. Perform the following steps in order to install the wheel and tire, aligning the previous marks:
5.1. Remove the wheel nuts securing the rotor to the hub and bearing assembly.
5.2. Install the wheel and tire assembly with the retaining nuts in the proper sequence.
5.3. Lower the vehicle.
6. Bleed the hydraulic brake system.
7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
8. Slowly release the brake pedal.
9. Wait 15 seconds, then repeat steps 7 and 8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
10. Fill the master cylinder to the proper level with clean brake fluid.