Brake Caliper Replacement - Front (Without J55)
Brake Caliper Replacement - Front (without J55)Caution: Refer to Brake Dust Caution.
Caution: Refer to Brake Fluid Irritant Caution
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice.
Removal 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, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise the vehicle and suitably support. Refer to Vehicle Lifting.
5. Remove the tire and wheel assembly.
6. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.
7. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
9. Remove the C-clamp from the caliper.
10. Remove the brake hose to caliper bolt attaching the brake hose to the brake caliper.
11. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
12. Plug the opening in the brake caliper and pipe to prevent fluid loss and contamination.
Important: Note the location of the caliper pin bolts. The upper caliper pin bolt, has a bushing as part of the assembly. The lower caliper pin bolt, is a solid design pin bolt.
13. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The upper caliper pin, has a bushing as part of the assembly. The lower caliper pin bolt, is a solid design pin bolt.
14. Remove the caliper (2) from the rotor and the caliper bracket (3).
15. Inspect the caliper bolt boots in the caliper bracket for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace any of the damaged caliper bolt boots.
Installation Procedure
1. If reusing the brake caliper pin bolts, wipe the old grease from the brake caliper pin bolts with a clean shop towel.
Important: DO NOT apply lubricant to the brake pad hardware.
2. Apply a thin coat of NIGLUBE grease to the brake caliper pin bolts. it is not necessary to apply lubricant to the brake pad hardware or the threads of the pin bolts.
3. Install the brake caliper (2) over the brake pads into the brake caliper bracket (3).
Notice: Refer to Fastener Notice.
Important: The upper caliper pin, has a bushing as part of the assembly. The lower caliper pin, is a solid design pin bolt.
4. Install the caliper pin bolts (1). The upper caliper pin bolt, has a bushing as part of the assembly. The lower caliper pin bolt, a solid design pin bolt. Ensure that the bolt boots fit securely around the caliper pin bolts. If the boots are damaged, they must be replaced.
^ Tighten the brake caliper pin bolts to 85 Nm (63 lb ft).
Important: Install NEW copper brake hose gaskets.
5. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
6. Install the brake hose to caliper bolt to the brake caliper.
^ Tighten the rear brake hose to caliper bolt to 45 Nm (33 lb ft).
7. Bleed the brake system.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal
10. Wait 15 seconds, then repeat steps 9-10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
11. Remove the 2 wheel lug nuts retaining the rotor to the hub.
12. Install the tire and wheel assembly.
13. Lower the vehicle.