Front Brake Caliper Replacement (1500 Series)
Front Brake Caliper Replacement (1500 Series)
Caution: Refer to Brake Dust Caution .
Caution: Refer to Brake Fluid Irritant Caution .
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 .
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
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.
Important: Cap or plug the brake hose to prevent brake fluid loss and contamination.
8. Remove the brake hose to caliper bolt.
Important: 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.
Important:
* 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.
Notice: Refer to Fastener Notice .
Important:
* 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.
Tighten the bolts to 100 N.m (74 lb ft).
4. Remove the cap or plug from the brake hose fitting end.
5. Install the brake hose to caliper bolt.
Tighten the bolt to 40 N.m (30 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure) (Service and Repair)Hydraulic Brake System Bleeding (Manual) (Service and Repair) .
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
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) .