Brake Caliper Replacement - Front

Brake Caliper Replacement - Front (1500 Series)

Caution: Refer to Brake Dust Caution in Service Precautions.

Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.

Removal Procedure





1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Raise and support the vehicle.
5. Remove the tire and wheel assembly.
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 pad.
2. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores.
3. Remove the C-clamps from the caliper.





7. Clean all dirt and foreign material from around the brake hose fitting.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

8. Remove the brake hose to caliper bolt.
9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end.
10. Remove the brake hose from the caliper.





11. Remove the brake caliper bolts.





12. Caution: 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.

Remove the caliper from the caliper bracket.

Installation Procedure





1. Install the caliper to the caliper bracket.





2. Notice: Refer to Fastener Notice in Service Precautions.

Install the brake caliper bolts.
Tighten the bolts to 100 Nm (74 lb ft).





3. Remove the rubber cap or plug from the exposed brake hose fitting end.
4. Assemble 2 NEW copper brake hose gaskets to the brake hose bolt, and brake hose.
5. Install the brake hose to caliper bolt.
Tighten the bolt to 40 Nm (30 lb ft).
6. Bleed the hydraulic brake system.
7. Install the tire and wheel assembly.
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary.