Front
REMOVALFRONT DISC BRAKE CALIPER
1. Raise and support the vehicle.
2. Remove the front wheel and tire assembly.
3. Drain a small amount of fluid from the master cylinder brake reservoir with a clean suction gun.
4. Disconnect the brake pad wear indicator harness connector.
5. Remove brake pad wear indicator (1) from caliper (2) by removing the retaining bolt.
6. Bottom the caliper piston into the caliper by prying the caliper over.
7. Remove the caliper support spring (2) by prying the spring out of the caliper (1).
8. Remove the caliper slide pin caps (3) and slide pins (2) from the caliper (1).
9. Remove the caliper (1) from the mounting bracket (2).
CAUTION: DO NOT spill the brake fluid on any painted surfaces. Brake fluid can damage paint.
10. Remove the brake hose (4) from the caliper (3).
11. Remove the inboard and outboard brake pads (2 and 3) from the caliper (1).
12. Disassemble the caliper to clean and inspect for wear and damage.
DISASSEMBLY - FRONT DISC BRAKE CALIPER
1. Drain the brake fluid from the caliper.
2. Take a piece of wood and pad it with a one-inch thickness of shop towels. Place this piece (1) on the outboard side of the caliper (2) in front of the piston.
WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE THIS COULD RESULT IN PERSONAL INJURY.
WARNING: DO NOT BLOW THE PISTON OUT OF THE BORE WITH SUSTAINED AIR PRESSURE. THIS COULD RESULT IN A CRACKED PISTON.
3. Remove the caliper piston (2) by using short bursts of low pressure air with a blow gun (1) through the brake hose port. Use only enough air pressure to ease the caliper piston out.
4. Remove the piston dust boot (2) with a suitable pry tool (1) and discard.
CAUTION: DO NOT SCRATCH PISTON BORE WHILE REMOVING THE SEALS.
5. Remove piston seal (2) from the caliper with a suitable tool (1).
6. Remove the caliper bleed screw.
7. Clean the caliper.
CLEANING - DISC BRAKE CALIPER
CAUTION: DO NOT use gasoline, kerosene, paint thinner or similar solvents. These products may leave a residue that could damage the piston and seal.
Clean the caliper components with clean brake fluid or Brake Clean� only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air.
INSPECTION - DISC BRAKE CALIPER
CAUTION: If the caliper piston is replaced, install the same type piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
Remove deposits on the piston using a soft brass wire brush or a rough shop towel. Do not clean piston with a polishing or emery cloth because this will damage the chrome-plated surface. Replace the piston if the chrome plated surface is damaged.
Clean anodized aluminum versions (piston and housing bore) with a soft rag only
If the piston is jammed or if the cylinder bores are scored or rusted, replace the complete fixed brake caliper and with the floating brake caliper, replace the cylinder housing. Remove small, light rust spots in the cylinder bore with a polishing cloth. Remove heavy rust spots in front of the groove for the piston seal using fine-grained emery paper (grain size 380 to 500).
ASSEMBLY - FRONT DISC BRAKE CALIPER
CAUTION: Dirt, oil, and solvents can damage caliper seals. Be sure the assembly area is clean and dry.
1. Lubricate the caliper piston, piston seals and piston bore with clean brake fluid.
Note: Verify seal is fully seated into seal groove and not twisted.
2. Install the new piston seal (2) into the seal groove.
3. Install the new dust boot (4) on the caliper piston (3) and seat the dust boot lip into the piston groove.
4. Stretch the dust boot (4) rearward to straighten the boot folds, then move the boot forward until the fold snaps into place.
5. Install the piston (3) into the caliper bore and press the piston down to the bottom of the caliper bore by hand or with the handle of a hammer.
6. Seat the dust boot (4) in caliper (1).
7. Install the new caliper bleed screw.
8. Install the caliper.
INSTALLATION
FRONT DISC BRAKE CALIPER
1. Install the inboard and outboard brake pads (2 and 3) onto the caliper (1).
2. Lubricate the slide pins (2) and slide pin bushings with silicone grease.
3. Install the caliper (1) on the mounting bracket (2).
4. Install the caliper slide pins (2). Tighten the slide pins to 25 Nm (18 ft. lbs.).
5. Install the caliper slide pin caps (3).
6. Install the brake pad wear indicator (2) onto the caliper. Tighten the bolt to 8 Nm (6 ft. lbs.).
7. Connect the brake wear indicator to the brake pad.
8. Install one end of the caliper support spring (2) in the top end of the caliper and under the mounting bracket (1).
9. Install the other end into the lower caliper hole (3).
10. Hold the spring (2) into the caliper hole (3) with your thumb while prying the end of the spring (2) out and down under the mounting bracket with a screwdriver.
CAUTION: Verify brake hose is not twisted or kinked before tightening the fitting.
11. Connect the brake hose (4) to the caliper (3).
12. Fill and bleed brake system.
^ Manual bleeding:
^ Pressure bleeding:
13. Install the wheel and tire assembly.
WARNING: DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS ACHIEVED.
14. Lower the vehicle.
15. Pump the brake pedal until the caliper pistons and the brake pads are seated and a firm brake pedal is achieved.
16. Top off the brake fluid reservoir with new fluid if necessary, and check for leaks.