Front
BRAKE CALIPER REPLACEMENT - FRONTRemoval Procedure
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
3. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
4. Remove the front tire and the wheel assembly.
5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.
6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
8. Remove the C-clamp from the caliper.
9. Remove the brake hose-to-caliper bolt (1) from the caliper.
Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
10. Plug the opening in the front brake hose (2) to prevent excessive brake fluid loss and contamination.
Important: Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design.
11. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.
12. Remove the caliper (2) from the rotor and the caliper bracket (3).
13. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots.
14. Inspect the caliper bolts (1) for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts (1) when installing the caliper.
Installation Procedure
1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth.
2. Apply lubricant, Delphi P/N 18046532, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing (2) and to the caliper pin bolt shank (3, 4). Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin (1), in front of the bushing.
3. Install the caliper (2) over the rotor and onto the caliper bracket (3).
Important: The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the caliper pin bolts (1). The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced.
^ Tighten the bolts to 95 Nm (70 lb ft).
Important: Install NEW copper brake hose gaskets.
5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
6. Install the brake hose-to-caliper bolt to the brake caliper.
^ Tighten the bolt to 54 Nm (40 lb ft).
7. Remove the 2 wheel lug nuts retaining the rotor to the hub.
8. Install the front tire and the wheel assembly.
9. Lower the vehicle.
10. Fill the master cylinder to the proper level with clean brake fluid.
11. Bleed the brake system.
12. Inspect the hydraulic brake system for brake fluid leaks.