Brake Caliper Replacement
REMOVAL PROCEDURE1. Remove 2/3 of the brake fluid from the master cylinder assembly.
2. Raise the vehicle and suitably support the vehicle.
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 Wheel Removal.
Reinstall two 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 attaching inlet fitting (5) only when the caliper (2) is to be removed from the vehicle for unit repair (overhaul). If only the shoe and linings are being replaced, there is no need to disconnect the inlet fitting (5).
Plug the exposed inlet fitting (5) in the caliper housing and the brake hose 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 installing 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).
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
2. Install the mounting bolts (1) and sleeve (4) assemblies (1).
3. Install the caliper (2) over the rotor into the knuckle.
^ Tighten the mounting bolt and sleeve assemblies to 51 Nm (38 ft. lbs.).
4. Install the inlet fitting, if the inlet fitting was removed.
^ Tighten the inlet fitting to 44 Nm (32 ft. lbs.).
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 Wheel Installation.
5.3. Lower the vehicle.
5.4. Tighten the wheel nuts. Refer to Wheel Fastner Specifications.
6. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
6.1. Bleed the caliper if the inlet fitting was removed. Refer to Brake Bleeding in Hydraulic Brakes.
6.2. Recheck the fluid level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
6.3. Recheck the brake pedal feel. If brake spongyness is present, refer to Brake System Testing and Inspection.