Caliper Removal and Installation, Front

Brake Caliper

Material:

Removal

WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. WARNING: If the vehicle is equipped with air suspension, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury.

If equipped, turn the air suspension service switch to the OFF position.

2. WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to Fire Suppression System.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
3. Remove the brake caliper flow bolt.
^ Discard the 2 copper washers.
4. Remove the 2 brake caliper bolts and the brake caliper.
^ Disconnect the brake pads from the caliper and remove the caliper.
5. Inspect the brake caliper for wear or damage. Inspect the guide pins and locating pins for wear or damage.
^ If leaks or damage are found, install a new brake caliper.

Installation

1. CAUTION: Make sure guide pin boots are correctly seated or damage to guide pins can occur.

NOTE: Tighten the lower brake caliper bolt first.

Install the brake caliper to the anchor plate and install the 2 brake caliper bolts.
^ Tighten to 36 Nm (27 ft. lbs.).
2. Using 2 new copper washers, position the brake hose and install the brake caliper flow bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
3. Bleed the brake system.
4. If the vehicle is equipped with air suspension, reactivate the system by turning on the air suspension switch.
5. Fill the brake master cylinder reservoir with brake fluid. Install the brake master cylinder filler cap.
6. Apply the brake pedal several times before driving the vehicle.
^ Test the brake system for normal operation.

7. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System.

If equipped with fire suppression system, repower the system.
8. If equipped, turn the air suspension service switch to the ON position.