Brake Caliper Removal and Installation

Brake Caliper

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: Loosen but do not remove the 2 brake caliper bolts.

Loosen the 2 brake caliper bolts.
3. Remove the brake caliper flow bolt and discard the copper washers.

4. CAUTION: Do not use the brake caliper sight hole to retract the 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 anchor plate bolts and position the brake caliper anchor plate, brake caliper, and brake pads aside.
^ Make sure the steering stop is supported when the brake caliper anchor plate bolts are removed.

5. CAUTION: When the brake pads are separated from the brake caliper, new brake pads must be installed. The brake pads are a one-time use only.

NOTE: The brake pads must be separated from the brake caliper before the brake caliper can be removed from the brake caliper anchor plate.

Using a suitable tool, separate the brake pads from the caliper.
6. Remove the 2 brake caliper bolts from the brake caliper and anchor plate assembly.
7. Remove the brake pads and spring clips from the brake caliper anchor plate.
8. Inspect the brake caliper.
^ If leaks or damaged boots are found, install a new brake caliper.

Installation
1. Position the brake caliper anchor plate and steering stop on the wheel knuckle and install 2 new bolts.
^ Tighten to 100 Nm (74 ft. lbs.).
2. Install the spring clips and brake pads into the anchor plate.
3. Position the brake caliper and install the 2 bolts.
^ Tighten to 60 Nm (44 ft. lbs.).

4. CAUTION: Make sure to protect the brake pads from contamination from the brake fluid during the brake flexible hose installation and the brake caliper bleeding.

CAUTION: Lubricate the brake caliper flow bolt threads and washers with clean brake fluid before installing the brake caliper flow bolt into the brake caliper.

Using 2 new copper washers, position the brake flexible hose and install the brake caliper flow bolt.
^ Tighten to 30 Nm (22 ft. lbs.).
5. Bleed the system.
6. With the vehicle engine running, apply 89 - 133 Nm (20 - 30 lbs.) of pressure on the brakes for approximately 1 minute, to make sure the brake pads adhere to the caliper before any contamination can be introduced.
7. Test the brakes for normal operation.