Caliper Removal and Installation, Front

Brake Caliper

Removal

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the brake caliper flow bolt and discard the 2 copper washers.

3. CAUTION: Do not use the caliper sight hole to retract pistons as this can damage the pistons and boots.

CAUTION: When removing the brake caliper, never allow it to hang from the brake hose. Provide a suitable support.

Remove and discard the 2 brake caliper bolts and remove the brake caliper.
4. Inspect the disc brake caliper.
^ If leaks or damaged boots are found, install a new brake caliper.

Installation
1. Position the brake caliper and install 2 new bolts.
^ Tighten to 34 Nm (25 ft. lbs.).
2. Using 2 new copper washers, position the brake flexible hose on the brake caliper and install the brake caliper flow bolt.
^ Tighten to 70 Nm (52 ft. lbs.).
3. Bleed the brake system.
4. Test the brakes for normal operation.