Removal and Installation

REMOVAL
WARNING:
- ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED.
- BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS SUCH AS A BRAKE/CLUTCH/SERVICE VACUUM. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS.
- IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS.
- OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA.

1. Raise and support the vehicle.

WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

2. Remove the wheel and tire assembly.





3. Disconnect the front brake hose.
1 Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.

WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.





4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.





5. Inspect the disc brake caliper for leaks.
- If leaks are found, disassembly is required.

INSTALLATION





1. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.





2. Install the front brake hose.
- Use new copper washers; connect the front brake hose.
- Install the front brake hose bolt.

3. Bleed the disc brake caliper.
4. Install the wheel and tire assembly.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.

5. Inspect the brake system operation.