Front Disc Brake Hardware Replacement (2500 Series)
Front Disc Brake Hardware Replacement (2500 Series)
Warning: Refer to Brake Dust Warning (Brake Dust Warning).
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 and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
6. Compress the brake caliper pistons.
1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad.
2. Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores.
3. Remove the C-clamps from the caliper.
7. Remove the brake caliper guide pin bolts.
Warning
Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
Caution: Refer to Brake Caliper Caution (Brake Caliper Caution).
8. Remove the brake caliper from the brake caliper bracket and support with heavy mechanics wire or equivalent.
9. Remove the brake caliper guide pin boots (4) from the brake caliper bracket (3).
Installation Procedure
1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper guide pin boots (4) to the caliper bracket (3).
3. Install the brake caliper to the caliper bracket.
Caution: Refer to Fastener Caution (Fastener Caution).
4. Install the brake caliper guide pin bolts and tighten to 108 Nm (80 lb ft).
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
6. Lower the vehicle.
7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
8. Slowly release the brake pedal.
9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained, to properly seat the brake caliper pistons and brake pads.
10. Slowly apply pressure to the brake pedal until a firm brake pedal is achieved.
11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling (Master Cylinder Reservoir Filling).