Brake Caliper Replacement-Rear (Export)

Removal Procedure
1. Use a suction gun in order to remove and DISCARD approximately 33 percent (1/3) of the brake fluid from the master cylinder.
2. Raise and support the vehicle.
3. Remove the tire and wheel.
4. Install two nuts to retain the rotor to the hub.





5. Install a large C-clamp (3) over the top of the brake caliper and against the back of the outboard brake pad.
6. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
7. If the brake caliper is going to be removed from the vehicle for unit repair (overhaul) or replacement, go to Step 8. If the brake caliper is not being replaced or overhauled, go to Step 13.





8. Remove the brake hose bolt (1).
9. Remove the brake hose (2) from the brake caliper.
10. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
11. Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and contamination.
12. Clean off any dirt or corrosion on the brake caliper near the brake hose fitting.





13. Remove the brake caliper bolts (1 and 3).

NOTICE: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

14. Remove the brake caliper (15) from the brake caliper bracket (12).
15. Use a strap or heavy gage wire in order to support the brake caliper.

16. Inspect the brake caliper piston boot (8) for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the brake caliper piston boot if damage exists.





17. Inspect the brake caliper bolt boots (4) for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the brake caliper bolt boots if damage exists.

18. Inspect the caliper bolts for corrosion or damage. If corrosion is found on the brake caliper bolt shaft, replace the brake caliper bolt, replace the brake caliper bolt bushing, and replace the brake caliper bolt boot. Do not attempt to polish away the corrosion.


Installation Procedure





1. Ensure that the caliper bolt bushings (4) and the caliper bolt boots (3) are properly installed.





2. Install the brake caliper (1) to the brake caliper bracket (2).





3. Use silicone grease to lubricate the brake caliper bolt shaft. Do not lubricate the threads.
4. Use silicone grease to lubricate the brake caliper bolt boots (4) in the brake caliper bracket (3).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Install the brake caliper bolts.
^ Tighten the brake caliper bolts to 43 Nm (32 lb ft).
6. Use a flat-bladed tool in order to install the brake caliper bracket boot over the shoulder of the brake caliper bolt.
7. Remove the plugs in the brake hose end.

Important: Install NEW copper brake hose gaskets (3).





8. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
9. Install the brake hose bolt to the brake caliper.
10. Remove the nuts securing the rotor to the hub.
11. Install the tire and wheel.
12. Lower the vehicle.
13. Fill the master cylinder to the proper level with clean brake fluid.





14. Bleed the brake caliper at the brake caliper bleeder screw.
15. Pump the brake pedal (3/4 of a full stroke) as many times as necessary to obtain a firm brake pedal.
16. Apply approximately 778 N (175 lbs.) of force to the brake pedal for ten seconds
17. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.