Front
REMOVAL - FRONT DISC BRAKE CALIPER1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir.
2. Raise the vehicle.
3. Remove front wheel and tire assembly.
4. Remove the anti-rattle spring from the outboard side of the caliper and adapter.
5. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers.
6. Remove the two caps in place over the caliper guide pin bolts.
7. Remove the two caliper guide pin bolts.
8. Remove caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed.
INSTALLATION - FRONT DISC BRAKE CALIPER
1. Completely retract the caliper piston back into piston bore of the caliper.
2. Lubricate both caliper adapter abutments where the shoes slide with a sufficient amount of Mopers Dielectric Grease, or equivalent.
NOTE: If shoes are being transferred or newly installed, make note that the inboard brake shoes are stamped L or R for left or right side of the vehicle. The P-slot or void on piston insulator must be positioned upward when brake caliper is mounted.
CAUTION: Use care when installing the brake caliper assembly onto the adapter, so that the seals on the caliper guide pin bushings do not get damaged by the adapter bosses.
3. Carefully position the brake caliper (with inboard shoe) over the brake rotor, outboard shoe and adapter.
4. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts.
5. Install the caps over the ends of the guide pin bolts.
6. Install the anti-rattle spring on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter.
CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers.
7. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 35 Nm (26 ft. lbs.).
8. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
9. Lower the vehicle.
10. Remove the brake pedal depressor (holding) tool.
11. Bleed the hydraulic brake circuit to the brake caliper.
12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.