Service Procedure

A. Inspect Date Code on Both Front Brake Calipers

1. Raise the vehicle on an appropriate hoist.





2. Inspect the date code on both front brake calipers. The date code is located on the back side of the caliper body (Figure 1).

> If the brake caliper date code number is 7079, replace the brake caliper.

Continue with Section B - Replace Front Brake Caliper(s).

> If the brake caliper date code number is higher or lower than 7079, brake caliper replacement is not required.

NOTE:
Replace the brake caliper if the date code is illegible.

B. Replace Front Brake Caliper(s)

NOTE:
The following procedure is only required if the front brake caliper(s) requires replacement per the inspection in Section "A." Very few vehicles are expected to require this repair.

1. Lower the vehicle from the hoist and install a prop rod on the brake pedal to keep pressure on the brake system.

NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system and will not allow the brake fluid to drain out of the brake fluid reservoir while the brake hose is disconnected from the brake caliper. This will facilitate bleeding only the caliper(s) that requires replacement instead of the entire brake system.

2. Raise the vehicle to a comfortable working height.

3. Remove front wheel and tire assembly.





4. Remove and discard the brake hose banjo bolt and copper washers (Figure 2).

5. Push the caliper pistons slightly into the caliper by using a C-clamp.

6. Remove the brake caliper slide pin bolts (Figure 2).





7. Remove the brake caliper from the brake adapter (Figure 3).

8. Destroy the old caliper so that it cannot be reused and discard.

9. Install the new caliper on the adapter.

10. Install the caliper slide pin bolts and tighten to 32 ft.lbs. (44 N.m) (Figure 2).

11. Gently lift one end of the slide pin bolt boot to equalize air pressure, then release the boot and verify that the boot is fully covering the slide pin.

12. Attach the brake hose to caliper using the new banjo bolt and one new copper washer on each side of the hose block.

Tighten the banjo bolt to 23 ft. lbs. (31 N.m).

CAUTION:
Verify brake hose is not twisted or kinked before tightening the banjo bolt.

13. Repeat steps 3 through 12 on the other caliper if it requires replacement.

14. Lower the vehicle from the hoist and remove the brake pedal prop rod.

15. Bleed the brake system using the following procedure:

a. Fill the brake master cylinder reservoir with DOT 3 brake fluid.





b. Attach one end of bleed hose to bleed screw on the brake caliper and insert opposite end in a clear container partially filled with brake fluid (Figure 4).
Be sure that the end of bleed hose is immersed in brake fluid.

c. Open the bleeder screw on the brake caliper, then have an assistant press and hold the brake pedal down. Once the pedal is down, close the bleeder screw and release the brake pedal. Repeat the bleeding process until the brake fluid stream in the container is clear and free of air bubbles.

d. Repeat Steps 15a through 15c on the other brake caliper if it was replaced.

16. Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs. (136 N.m).

17. Lower the vehicle from the hoist.

18. Verify brake fluid level and add fluid as required.

19. Verify that there are no brake fluid leaks and that the brakes operate properly.