Brake Caliper Replacement

Brake Caliper Replacement

Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions.





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 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 the vehicle.

4. Remove the tire and wheel assembly.
5. Hand tighten 2 wheel nuts in order to retain the rotor to the hub.
6. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor:
6.1. Install a large C-clamp (2) over the top of the caliper housing and against the back of the outboard pad.
6.2. Slowly tighten the C-clamp (2) until the piston is pushed into the caliper bore far enough to slide the caliper assembly off the rotor.





7. Remove the brake hose to caliper bolt (1).
8. Remove and discard the 2 copper brake washers (3).
9. Plug the caliper housing and brake hose in order to prevent fluid loss and contamination. The cover on the bleeder will work as a plug in the caliper.





10. Remove the brake caliper bolts. It may be necessary to use a wrench in order to hold the brake caliper pin from rotating.





11. Remove the 2 guide pins (5) from the caliper mounting bracket (3).
12. Inspect the boots (4) for cuts or nicks that would allow contamination to enter the caliper mounting bracket (3).
13. Inspect the guide pins (5) and caliper mounting bracket (3) for corrosion.

Important: Do not attempt to polish away corrosion.

14. If the guide pin boots (4) are damaged or the guide pins (5) and caliper mounting bracket (3) show signs of corrosion replace with new parts.

Installation Procedure





1. Lubricate the caliper pins (5) and the boots (4) with high temperature silicone brake lubricant or equivalent.
2. Install the caliper pins (5) and the boots (4) to the caliper mounting bracket (3).





3. Install the caliper to the caliper mounting bracket.





4. Install the caliper bolts (1) thru the caliper (2) and into the caliper pins (5).
- Tighten the 2 caliper bolts to 31 Nm (23 lb ft).

Notice: Refer to Fastener Notice in Service Precautions.





5. Install the brake hose to caliper bolt (1) with 2 new copper washers (3) and the brake hose (2) to the caliper.
- Tighten the brake hose to caliper bolt to 50 Nm (37 lb ft).

6. Remove the 2 wheel lug nuts retaining the rotor to the hub.
7. Install the wheel and tire assembly.
8. Lower the vehicle.
9. Fill the master cylinder to the proper level with clean brake fluid.
10. Bleed the hydraulic brake system.
11. Inspect the hydraulic brake system for leaks.