Front

Brake Caliper Replacement-Front

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 suitably support the vehicle. Refer to Vehicle Lifting.
4. Remove the front tire and the wheel assembly.
5. Hand tighten two wheel lug nuts to retain the rotor to the hub.





6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
8. Remove the C-clamp from the caliper.





9. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the two copper brake hose gaskets (3).These gaskets may be stuck to the brake caliper and/or the brake hose end.
10. Plug the opening in the front brake hose (2) in order to prevent excessive brake fluid loss and contamination. Do not pinch off the brake hose with any tools.





11. Remove the caliper bolts (3).
12. Remove the caliper (1) from the rotor and the caliper bracket (2).
13. Inspect the caliper bolt boots in the caliper bracket for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the caliper bolt boots if damage exists.





14. Inspect the caliper bolts (1) for corrosion or damage. Do not attempt to polish away corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper.

Installation Procedure

1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent.
2. Dry the brake caliper pin bolts and retainers, using non-lubricated, filtered air.
3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware.





4. Install the caliper (1) over the rotor and the caliper bracket (2). Ensure that the bushings are in place.





5. Lubricate the caliper bolts (1). Use silicone grease. Do not lubricate the threads.
6. Lubricate the two bolt boots in the caliper bracket. Use silicone grease.

Notice: Refer to Fastener Notice in Service Precautions.





7. Install the caliper bolts (3). Ensure that the bolt boots fit securely in the groove of the pin bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced.
^ Tighten the caliper bolts to 95 Nm (70 lb ft).

Important: Install NEW copper brake hose gaskets.





8. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
9. Install the brake hose-to-caliper bolt to the brake caliper
^ Tighten the brake hose bolt to 54 Nm (40 lb ft).
10. Remove the two wheel lug nuts retaining the rotor to the hub.
11. Install the front tire and the wheel assembly.
12. Lower the vehicle.
13. Fill the master cylinder to the proper level with clean brake fluid.
14. Bleed the brake system.
15. Inspect the hydraulic brake system for brake fluid leaks.