Front Brake Caliper Replacement (1500 Series)
Front Brake Caliper Replacement (1500 Series)
Warning:
Refer to Brake Dust Warning Brake Dust Warning.
Warning:
Refer to Brake Fluid Irritant Warning Brake Fluid Irritant Warning.
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, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Removal and Replacement.
6. Compress the brake caliper pistons.
1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad.
2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores.
3. Remove the C-clamps from the caliper.
7. Clean all dirt and foreign material from the brake caliper.
Note:
Cap or plug the brake hose to prevent brake fluid loss and contamination.
8. Remove the brake hose to caliper bolt.
Note:
Ensure the washers are not still attached to the brake hose or the brake caliper.
9. Remove and discard the 2 copper brake hose gaskets.
10. Remove the brake hose from the brake caliper.
Note:
* DO NOT use any air tools to remove or install the brake caliper bolts. Use hand tools ONLY.
* Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the brake caliper bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.
11. Using an open end wrench to hold the guide pin, loosen the brake caliper bolts.
12. Remove the brake caliper bolts.
13. Remove the brake caliper from the mounting bracket.
Installation Procedure
1. Install the caliper to the caliper bracket.
2. Install the brake caliper bolts.
Caution:
Refer to Fastener Caution Fastener Caution.
Note:
* DO NOT use any air tools to remove or install the brake caliper bolts. Use hand tools ONLY.
* Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the brake caliper bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.
3. Using an open end wrench to hold the guide pins while tightening the brake caliper bolts to 100 Nm (74 lb ft).
4. Remove the cap or plug from the brake hose fitting end.
5. Install the brake hose to caliper bolt and tighten to 40 Nm (30 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure)Hydraulic Brake System Bleeding (Two-mode Hybrid) Hydraulic Brake System Bleeding (Two-Mode Hybrid)Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual).
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Removal and Replacement.
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling.