Rear Caliper

REAR CALIPER

TOOLS REQUIRED
^ KM-286 Installing Shackle

REMOVAL

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

1. Raise vehicle on hoist.





2. Remove rear wheel and tire assembly.
3. Remove brake pads.
4. Remove brake pipe from rear caliper. Plug open brake pipe to prevent brake fluid loss and contamination.
5. Remove caliper to rear axle control arm fasteners.





6. Remove caliper assembly.

DISASSEMBLY

IMPORTANT: The rear caliper has a dual piston design. The caliper must not be completely disassembled. Only disassemble one piston at a time.





1. Using a small screwdriver, carefully pry piston boot clamp ring from boot.
2. Remove piston boot.

CAUTION: TO PREVENT BODILY INJURY, MAKE SURE TO KEEP FINGERS OR OTHER BODY PART AWAY FROM PISTON DURING REMOVAL.

NOTICE: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.





3. Block opposite piston with holding tool Installing Shackle KM-286 and carefully remove piston from caliper by applying low pressure, non-lubricated, compressed air into caliper inlet hole.





4. Remove piston seal from groove of caliper.





5. Remove bleeder valve and bleeder valve cap from caliper assembly.
6. Clean all parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in caliper body and bleeder valve.
7. Inspect piston for scoring, nicks, cracks, wear or corrosion. Replace piston if any damage is found.

IMPORTANT: Do not hone caliper bore.

8. Inspect caliper body piston bore for scoring, nicks, wear or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace the caliper.





9. Inspect seal groove in caliper for nicks or burrs. If present, replace caliper.

ASSEMBLY
1. Install bleeder valve and cap into caliper assembly.
Torque:
Rear Caliper Bleeder Valve: 6 Nm (53 lb in)

NOTICE: Make sure seal is not twisted in the groove.

2. Lubricate new piston seal with clean brake fluid and install into caliper seal groove.





3. Insert piston boot into caliper groove.

IMPORTANT: Make sure that piston boot is smoothly seated in counter bore of caliper body.

IMPORTANT: Piston face has a notched surface cap. Position relief notch toward bottom side of caliper.

4. Insert piston into caliper bore.
5. Repeat disassembly steps I through 4 and assembly steps 1 through 4 for opposite caliper piston.

INSTALLATION

NOTICE: Clean caliper support bracket fasteners thoroughly with brake and choke cleaner (P/N 21007432 or equivalent). Apply Loctite 272 (R) Threadlocker (or equivalent) to caliper support bracket fasteners. If Loctite 272 (R) Threadlocker (or equivalent) is not available, new caliper support bracket fasteners must be used.





1. Install caliper assembly to rear axle control arm and tighten.
Torque:
Rear Caliper-to-Rear Axle Control Arm Bolts: 80 Nm (59 lb ft)
2. Install brake pipe to caliper assembly.
Torque:
Brake Pipe-to-Rear Caliper: 16 Nm (12 lb ft)

IMPORTANT: Never replace brake pads on one side of axle only. Left and right side brake pads must be replaced only as axle sets.





3. Install brake pads into caliper.





4. Apply small amount of silicone grease to retaining pins.

IMPORTANT: Check to ensure brake pads move freely in guide.

5. Install brake pad retaining spring, and drive brake pad retaining pins in from inside outward.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.

6. Bleed brakes.
7. Position wheel and tire assembly onto hub.
8. Install wheel bolts and tighten in a crisscross pattern.
8.1 Hand tighten all five wheel bolts.
8.2 Use a torque wrench to tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 lb ft)
8.3 Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 lb ft)
9. Lower vehicle from hoist.

CAUTION: IF THIS OPERATION IS NOT CARRIED OUT, BRAKES WILL NOT OPERATE PROPERLY DURING INITIAL BRAKE APPLICATIONS.

10. Prior to operating vehicle, depress brake a few times until brake pads are seated against rotor.