Dual Piston

Brake Caliper Replacement-Front (Dual Piston)

Removal Procedure

1. Remove two-thirds of the brake fluid from the master cylinder reservoir.
2. Raise the vehicle and support the vehicle with proper safety stands.




3. Remove the tire and wheel assembly.




4. Position a C-clamp over the outer brake pad and the caliper.
1. Tighten the C-clamp until the piston bottoms in the caliper bore.
2. Remove the C-clamp.




5. Disconnect the brake hose from the caliper when removing the caliper for overhaul or replacement.
1. Disconnect the brake hose fitting and two gaskets.
2. Discard the gaskets.
3. Plug the hole in the caliper housing and in the brake hose fitting.
6. Remove the caliper guide pin bolts.
7. Remove the caliper from the caliper bracket.

Notice: Do not allow the brake components to hang from the flexible brake hoses. Damage to the brake hoses could result.

8. If you did not disconnect the brake hose, suspend the caliper.

Inspection Procedure

1. Inspect the caliper guide pin bolts for corrosion. Do not polish away any corrosion.
Replace corroded bolts.
2. Inspect the linings for wear.
Replace the linings if the linings are tapered beyond 0.15 mm (0.006 in).
3. Inspect the brake hose fitting bolt. If the through-hole is blocked, remove the blockage or replace the bolt.


Installation Procedure




1. Install the linings.

Important: Lift the inner edge of the caliper boots next to the pistons. Press out any frapped air. The boots must lay flat below the level of the piston faces.

2. Install the caliper over the rotor and into the anchor bracket.




3. Install the two caliper guide pin bolts to the caliper bracket.
Tighten
Tighten the bolts to 115 N.m (85 lb ft).

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.




4, Install the brake hose fitting, two new gaskets, and the brake hose fitting bolt, if removed.
Tighten
Tighten the brake hose bolt to 54 N.m (40 lb ft).
5. Bleed the caliper, if separated from the brake hose in removal.
6. Install the tire and wheel assembly.
7. Remove the safety stands and lower the vehicle.
8. With the engine running, firmly pump the brake pedal three times.
9. Inspect the brake system for leaks.