Rear Brake Caliper Replacement (2500 Series)

Rear Brake Caliper Replacement (2500 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 brake pad.

2. Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores.

3. Remove the C-clamps from the caliper.

7. Clean all dirt and debris from the brake caliper and fittings.





Note:
Cap or plug to the brake hose to prevent brake fluid leakage and contamination of the brake system.

8. Remove the brake hose to caliper bolt.

9. Remove the brake hose from the caliper.

Note:

* Ensure that the copper gaskets are not attached to the brake caliper or the brake hose.

* DO NOT re-use the copper gaskets, replace them with NEW.

10. Remove and discard the 2 copper brake hose gaskets.





11. Remove the brake caliper guide pin bolts from the brake caliper.

12. Remove the brake caliper from the mounting bracket.

Installation Procedure

1. Install the brake caliper to the mounting bracket.

Caution:
Refer to Fastener Caution Fastener Caution.





2. Install the brake caliper guide pin bolts and tighten to 108 Nm (80 lb ft).

3. Remove the cap or plug from the brake hose to caliper fitting.





Note:
Install 2 NEW copper brake hose gaskets.

4. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose.

5. Install the brake hose to caliper bolt and tighten to 45 Nm (33 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.