Front Caliper

REMOVAL

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST.





1. Raise vehicle on hoist.
2. Remove wheel and tire assembly.
3. Remove brake hose from caliper. Plug openings in caliper and hose to avoid fluid loss and contamination.





4. Remove brake pad retaining spring from caliper.





5. Remove caliper-to-bracket guide pins.
6. Remove caliper from support bracket.





7. Remove Pads from caliper and inspect;
a. Guide pin sleeves and covers for damage. If damaged, replace.
b. Piston boot for deterioration. If damaged overhaul caliper.
c. Guide pin for damage or corrosion. Replace if damaged or corroded (do not attempt to clean away corrosion).

DISASSEMBLY





1. Using a small screw driver, remove piston boot. (slowly pry up one end of boot).

CAUTION: TO PREVENT BODILY INJURY, MAKE SURE TO KEEP FINGERS OR OTHER BODY PARTS AWAY FROM PISTON DURING REMOVAL.

NOTICE: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.





2. Remove piston from caliper body by applying low pressure, non-lubricated, compressed air into caliper inlet hole.

NOTICE: To prevent damage to caliper body bore, use a small wooden or plastic (non metal) device to extract seal.





3. Remove piston seal from groove in caliper.
4. Remove bleeder valve and bleeder valve cap from caliper body.
5. Clean all parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in caliper body and bleeder valve.





6. Inspect piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found.
7. Inspect caliper body piston bore for scoring, nicks, wear, or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace caliper.

IMPORTANT: Do not hone caliper bore.

8. Inspect seal groove in caliper bore for nicks or burrs. If present, replace caliper.

ASSEMBLY





1. Install bleeder valve into caliper body assembly.
Torque: 6 Nm (53 lb in)
2. Install bleeder valve cap.

NOTICE: Make sure seal is not twisted.

3. Lubricate new piston seal with clean brake fluid and install seal into caliper seal groove.





4. Install piston boot into caliper. Boot must sit in caliper groove.
5. Lubricate outside diameter of piston with clean brake fluid.

NOTICE: Inner lip of piston boot must engage in groove of piston.

6. Install piston into caliper body. Push piston all the way to bottom of caliper bore.

INSTALLATION





1. Make sure caliper piston is bottomed fully in its caliper bore.
2. Lubricate pin sleeve with silicon grease, and install into caliper.
3. Lubricate straight section (not threads) of guide pins with silicone grease.

NOTICE: Install linings so identification mark is toward front of vehicle.

IMPORTANT: Before installing new brake pads, ensure that piston is correctly positioned, two raised thrust surfaces of piston must lie horizontally.

IMPORTANT: Remove all rust and corrosion from caliper brackets when installing brake pads. If installing used brake pads, remove all rust and corrosion from ends of brake pads and from the notch. Make sure brake pads move freely in caliper bracket when brakes are assembled.





4. Install inner and outer brake pads into caliper.





5. Install caliper body onto caliper support.
6. Install guide pins and tighten.
Torque: 30 Nm (22 lb ft)





7. Install brake pad retaining spring.

NOTICE: Be sure that front brake hose is routed properly. Be careful not to install front brake hose with a twist. Incorrect front brake hose installation could result in brake failure.





8. Connect brake hose to caliper using new washers.
Torque: 40 Nm (30 lb ft)
9. Bleed brakes.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel bolts to loosen in service.

10. Position wheel and tire assembly onto hub.
11. Install wheel bolts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.
Torque: 125 Nm (92 lb ft)
12. Lower vehicle from hoist.