Unit Replacement

NOTE: Replace all components included in repair kits used to service this caliper.
- Lubricate rubber parts with clean brake fluid to ease assembly.
- Do not use lubricated shop air on brake parts as damage to rubber components may result.
- If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system.
- Replace shoe and linings in axle sets only.
- The torque values specified are for dry, unlubricated fasteners.
- Perform service operations on a clean bench, free from all mineral oil materials.

Caliper Components:

REMOVE OR DISCONNECT
1. Two-thirds of brake fluid from master cylinder.
2. Raise vehicle and suitably support.
3. Mark relationship of wheel to axle flange.
4. Wheel and tire.
5. Reinstall two wheel nuts to retain rotor.
6. If caliper is to be removed for unit repair, remove bolt attaching inlet fitting, and plug opening in caliper and/or pipe to prevent fluid loss and contamination. If only shoes and linings are being replaced, do not disconnect inlet fitting.

Compressing Piston Into Bore:

7. Push piston into caliper bore to provide clearance between linings and rotor.
a. Install a large C-clamp over top of caliper housing and against back of outboard shoe.
b. Slowly tighten C-clamp until piston is pushed into caliper bore far enough to slide caliper off rotor.

Caliper Attachment:

8. Caliper mounting bolts and sleeves.

Suspending Caliper From Strut:

9. Caliper. If only shoes and linings are being replaced, suspend caliper with a wire hook from strut.Inspect Mounting bolts and sleeves for corrosion. Bushings for cuts and nicks. If damage is found, use new parts when installing caliper. Do not attempt to polish away corrosion.

INSTALL OR CONNECT

Lubricating Caliper Cavity:

1. Liberally coat ID of bushings with silicone grease.
2. Caliper.
3. Mounting bolts and sleeves.

NOTE: Mounting bolts and sleeves should slide through bushings with only hand pressure applied. If greater force is required, or mechanical assistance is needed, do the following:
a. Remove bolts and sleeves along with bushings.
b. Inspect mounting bores for corrosion. If bores show signs of corrosion, remove corrosion by using a 1-inch wheel cylinder honing brush.
c. Clean bores with clean, denatured alcohol.
d. Install bushings and relubricate.

4. Inlet fitting, if removed. Tighten Mounting bolts to 51 Nm (38 ft. lbs.). Inlet fitting to 45 Nm (33 ft. lbs.).
5. Wheel and tire, aligning previous mark. Remove wheel nuts securing rotor to hub. Lower vehicle. Torque wheel nuts.
6. Fill master cylinder to proper level with clean brake fluid. Bleed caliper if inlet fitting was removed. Recheck fluid level.