Front

Brake Caliper Replacement - Front
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, 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 support the vehicle. Refer to Vehicle Lifting.
4. Remove the tire and wheel.
5. Install two 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 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 (3).

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

14. Remove the brake caliper from the brake caliper bracket.
15. Inspect the piston boot for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the piston boot if damage exists. Refer to Brake Caliper Overhaul - Front.





16. Inspect the brake caliper bolt boots (4) for the following conditions:
^ Cuts
^ Tears
^ Deterioration
Replace the bolt boots if damage exists. Refer to Brake Caliper Bracket Replacement - Front.

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

Installation Procedure





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





2. Install the caliper (1) to the caliper bracket.
3. Lubricate the brake caliper bolt shaft. Do not lubricate the bolt threads.





4. Lubricate the brake caliper bolt boots (4) in the caliper bracket (3).

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the brake caliper bolts.
Tighten the brake caliper bolts to 85 Nm (63 lb ft).
6. Use a flat-bladed tool in order to install the caliper bracket boot over the shoulder of the 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.
Tighten the brake hose bolt to 54 Nm (40 lb ft).
10. Remove the nuts securing the rotor to the hub.
11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation.
12. Lower the vehicle.
13. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling.
14. Bleed the brake system if the brake hose was disconnected from the brake caliper. Refer to Brake Bleeding.
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.