Caliper - Standard Brakes

Caliper - Brake





Removal

WARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.

CAUTION:
- Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.
- Remove brake fluid spillage immediately from paint work, with clean water.
- A new brake hose must be installed when replacing a front brake caliper.
- The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.

1. Open engine compartment and fit paint work protection covers to fenders.

2. Raise vehicle on a four-post lift.

3. Raise front of vehicle and support on stands.

4. Remove front wheels.

NOTE: The following three pictorial procedures must be carried-out to minimize brake fluid loss when disconnecting the brake hose.





5. Open Left-Hand-Front and Left-Hand-Rear caliper bleed nipples.
- Connect a bleed tube and container to the calipers.
- Open bleed nipples.





6. Depress and hold down brake pedal at the specified measurement using the special tool.
- Position tool between brake pedal and seat frame.
- Turn the tool wheel until the brake pedal is held 60mm down from its released position.





7. Close bleed nipples on both calipers.
- Remove bleed tubes and containers.
- Tighten front bleed nipple to 4 - 6 Nm.
- Tighten rear bleed nipple to 8 - 11 Nm.

CAUTION: A new brake hose must be installed when replacing a front brake caliper.





8. Disconnect brake hose from brake tube.
- Unscrew brake tube union nut.
- Remove nut from hose.
- Remove hose from bracket.
- Fit plug to brake tube.





9. Remove brake hose from caliper.
- Unscrew brake hose.
- Fit plugs to caliper port.
- Discard brake hose.





10. Remove caliper housing from caliper carrier.
- Remove anti-rattle spring.
- Remove dust covers.
- Remove guide pins.
- Remove housing from carrier.

NOTE: The inner brake pad is fitted with a clip which secures the pad into the caliper piston.





11. Remove and discard brake pads. (See Caution above).





12. Remove brake carrier from vertical link.
- Remove bolts.
- Remove carrier.

13. Remove brake dust and clean caliper mating surfaces. See Warning above.

Installation





1. Install caliper carrier to vertical link.
- Align carrier to vertical link.
- Install and tighten bolts to 120 - 160 Nm.

NOTE: Clean caliper piston to pad mating surface.





2. Install brake pads into caliper housing. (See Caution above).
- Remove plug from port and slowly retract piston into caliper housing.
- Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of inner pad into caliper piston.





3. Install caliper housing to caliper carrier.
- Align housing to carrier.
- Install and tighten guide pins to 25 - 30 Nm.
- Install dust covers.
- Install anti-rattle spring.

NOTE: The brake hose must only be installed with the vehicle's body supported and the suspension hanging in the straight ahead position.





4. Install and tighten brake hose to caliper housing to 10 - 14 Nm.

NOTE: Make sure the brake hose does not twist when tightening the hose lock-nut.





5. Connect brake hose to brake tube.
- Position hose thread through bracket.
- Install and tighten locking nut to 15 - 20 Nm.
- Install and tighten brake-tube union nut.

6. Remove special tool from brake pedal.

7. Fit wheels.

NOTE: Make sure the brake hose is routed correctly.

8. Remove stands and lower vehicle.

9. Bleed brake hydraulic system.