Caliper - Standard Brakes

Caliper - Brake

Special Service tools





Brake Pedal Hold Tool

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.

CAUTION: Remove brake fluid spillage immediately from paint work, with clean water.

CAUTION: 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 luggage compartment lid and fit suitable paintwork protection equipment.

2. Raise vehicle on a four-post lift.

3. Raise rear of vehicle and support on stands.

4. Remove rear wheel.

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 60 mm 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.





8. Disconnect brake hose from rear caliper housing.
- Install plugs to caliper and brake hose.





9. 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.





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





11. Remove caliper carrier from hub carrier.
- Remove bolts.
- Remove carrier.

12. Clean all mating surfaces and remove brake dust. See Warning above.

Installation





1. Install caliper carrier to hub carrier.
- Align carrier to hub carrier.
- Install and tighten bolts to 54 - 66 Nm.





2. Make sure piston is fully retracted into caliper housing.
- Remove plug from caliper housing.
- Retract piston.





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





4. 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.





5. Connect brake hose to caliper housing.
- Remove plugs.
- Install and tighten bolt to 30 - 40 Nm.

6. Remove special tool from brake pedal.

7. Fit wheels.

8. Remove stands and lower vehicle.

9. Bleed brake hydraulic system.