Brake Caliper Replacement

Removal Procedure





1. Remove 2/3 of the brake fluid from the master cylinder assembly.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Mark the relationship of the wheel to the hub and bearing assembly in order to ensure proper wheel balance upon reassembly.
4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
Reinstall 2 wheel nuts in order to retain the rotor to hub and bearing assembly.
5. Push the piston into the caliper bore in order to provide clearance between the linings and the rotor.
6. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe.
Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough in order to slide the caliper assembly off the rotor.





7. Remove the bolt that attaches the inlet fitting (5) only when the caliper (2) is removed from the vehicle for unit repair (overhaul). If only the linings are being replaced, you do not need to disconnect the inlet fitting (5).
Plug the exposed inlet fitting (5) in the caliper housing and the brake hose in order to prevent fluid loss and contamination.
8. Remove the caliper mounting bolts (1) and sleeve assemblies.





9. Remove the caliper from the rotor and knuckle.
^ Do not let the caliper (2) hang from the brake hose. Damage may occur.
^ If the caliper assembly is not being removed from the vehicle for unit repair, suspend the caliper with a wire hook from the strut (1).





10. Inspect the mounting bolts (1) and sleeve (4) assemblies for corrosion.
11. Inspect the bushings (2) for cuts and nicks.
12. If damage to either part is found, replace with new parts when you install the caliper.
13. Do no attempt to polish away corrosion.

Installation Procedure





1. Liberally coat the inside of the diameter of the bushings (4) with silicone grease (4).
2. Install the mounting bolts (1) and the sleeve (4) assemblies.





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the caliper (2) over the rotor into the knuckle.

^ Tighten the mounting bolt and sleeve assemblies to 51 Nm (38 lb ft).





4. Install the inlet fitting, if the inlet fitting was removed.

^ Tighten the inlet fitting to 44 Nm (32 lb ft).

5. Perform the following steps in order to install the wheel and tire, aligning the previous marks:
5.1. Remove the wheel nuts securing the rotor to the hub and bearing assembly.
5.2. Install the wheel and tire assembly with the retaining nuts in the proper sequence. Refer to Tire and Wheel Removal and Installation.
5.3. Lower the vehicle.
6. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling.
6.1. Bleed the caliper if the inlet fitting was removed. Refer to Hydraulic Brake System Bleeding.
6.2. Recheck the fluid level. Refer to Master Cylinder Reservoir Filling.
6.3. Recheck the brake pedal feel.