Front

Front Disc Brake Caliper/Description:

REMOVAL
1. Raise and support vehicle.
2. Remove the wheel and tire assembly. Use care to avoid damage to, or interference with, the wheel cylinder bleeder screw during removal.
3. Mark disc brake caliper assembly to make sure it is installed on correct side during installation.

Disc Brake Caliper/Hose:

4. Remove hollow retaining bolt that connects hose to disc brake caliper. Remove hose from caliper and plug hose.
5. Remove and discard two copper sealing washers
6. Remove two caliper caliper guide pin bolts.
7. Lift disc brake caliper off front disc brake rotor using rotating motion.

Retracting Caliper:

INSTALLATION
1. Use a 10 cm (4 inch) C-clamp and wood block approximately 70 mm x 25 mm (2 3/4 inch x 1 inch), and 19 mm (3/4 inch) thick to seat the caliper piston in its bore. This must be done to provide clearance for the disc brake caliper to fit over the front disc brake rotor during installation.
2. Inspect disc brake caliper locating pin and locating pin boots. They should move freely and boots should not be torn. Replace or service as required.
3. Position disc brake caliper assembly over pads and rotor.
4. Install two caliper guide pin bolts and tighten to 28-36 Nm (21-26 ft. lbs.).
5. Remove plug and install front brake hose on disc brake caliper with a new sealing washers on each side of the fitting. Install retaining bolt through fitting and washers. Tighten to 40-60 Nm (30-44 ft. lbs.).
6. Bleed serviced caliper.

NOTE: Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.

7. Install wheel and tire assembly, using Rotunda Accutorq(r) Lug Nut Sockets or equivalent on 1/2 inch drive air impact wrench or torque wrench to tighten lug nuts to 115-142 Nm (85-104 ft. lbs.).
8. Lower vehicle.
9. Pump brake pedal several times to position brake shoes and linings. Refill brake master cylinder with high performance Dot-3 brake fluid as necessary.
10. Road test vehicle.